Development Of Radial-Axial Ring Rolling Experimental Test Equipment

The radial-axial ring rolling is a continuous and local plastic forming process by usingheavy duty radial-axial ring rolling mills, which is utilizes to produce seamless rings with largediameter. Because of energy saving, material saving, high efficiency, high quality and othersignificant advantages, radial-axial ring rolling technology reduces the costs of producing largehigh-powered ring greatly, which attracts extensive attentions.Up to now, due to lack of appropriate experimental equipments, experimental studies oflarge rings mainly rely on heavy duty radial-axial ring rolling mills in radial-axial ring rollingresearches which is difficult and expensive. Meanwhile, because of the complexity ofradial-axial ring rolling, it is essential to carry out a large number of experimental researches.Therefore, the development of radial-axial ring rolling experimental test equipment is critical.In this paper, a radial-axial ring rolling experimental equipment is designed and developedby referring to the heavy duty radial-axial ring rolling mill D53K-2500A in production, andbased on the principle of similarity. The structure stiffness and strength of both radial rollingsystem and axial rolling system are analyzed by using ANSYS. Based on the principle ofsimilarity, the mathematical relationship and calculation method between experimental rollingforces and actual ones in the process of radial-axial ring rolling are established. The mainresearch contents are as follows:(1) Based on the principle of similarity, experimental materials are determined. They arelead, plastic clay and wax. The mathematical relationship and calculation method betweenexperimental rolling forces and actual ones in the process of radial-axial ring rolling areestablished. The basis of experimental and theoretical studies is provided in the research.(2) The heavy duty radial-axial ring rolling mill D53K-2500A is used as the mainreference model. Based on the principle of similarity and the theory of ring rolling, maintechnical parameters are calculated and the design of an experimental equipment is completed.Three-dimensional models of overall structure, radial rolling system and axial rolling systemare drawn by SolidWorks.(3) The structure stiffness and strength of both radial rolling system and axial rollingsystem are analyzed by using ANSYS. The results show that the stiffness and strength of mandrel components of the radial rolling system and the axial rolling system can satisfy therequirements; but the stiffness and strength of main roll components of the radial rolling systemcan not satisfy the requirements. Structural modifications of main roll components are needed.Under the same load, the maximum value of Von Mises stress and equivalent strain of mandrelcomponents decreases with increasing the axial size of the ring. However, the maximum valueof deformation is increase. The maximum value of Von Mises stress, equivalent strain anddeformation of main roll components increase with increasing the axial size of the ring, whichis a linear trend.(4) For unreasonable designs, the structure of main roll components is modified. Then thestructure stiffness and strength of revised main roll components are analyzed by ANSYS. Theresults show that the stiffness and strength of revised main roll components can satisfy therequirements.In summary, a radial-axial ring rolling experimental equipment is designed and developedin this paper. The mathematical relationship and calculation method between experimentalrolling forces and actual ones in the process of radial-axial ring rolling are established. Thestructure stiffness and strength of experimental equipment are analyzed. The structure of mainroll components is modified. Research results can lay the foundation of the research ofradial-axial ring rolling experimental equipment.