Structure Design And Optimization Of 250mm Servo-driven Forging Roll And Application Of Numerical Simulation

Roll forging is widely used because of its advantages of easy automation, high production efficiency, high material utilization rate, small forming stable load and the good quality of workpiece. Roll forging process has been improved rapidly with the efforts of researchers and technicians while the development of forging roll is relatively slow. Presently, the servo-driven forging roll abroad is more mature than domestic, and the research and application of servo technology that employed to drive the forging roll directly have not been reported.The main research contents of this paper are:(1) The prototype of 250 mm servo-driven forging roll was designed, including the choice of servo-driven scheme, the design of technical parameters and the layout of structures.(2) Based on virtual prototype technology, the static analysis of the forging roll was carried out, and the deformation regularity of the frame and roll forging were obtained by simulating the four deformation steps of forging roll. The stiffness and strength of the machine were verified, and the weakness was found out to prepare for the subsequent optimization.(3) The modal and transient dynamic analysis of the forging roll was carried out based on virtual prototype technology.(4) The frame structure of the machine was optimized as the target of minimum the machine's mass based on the orthogonal experiment. The mechanical deformation of the frame under different parameters is analyzed, and the structure of the frame is improved.(5) Roll forging process of 6061 aluminum was designed based on the characteristics of the speed of the forging roll, to explore the influence of the roll forging speed on the roll forging force, roll forging torque and roll forging power, etc.The results of the study are as below:(1) The designed 250 mm servo-driven forging roll can work at different speed with the range of 0~150r/min.(2) The stiffness of the frame of the forging roll is 848 k N/mm, greater than the allowable stiffness 350 k N/mm, the maximum effective stress is 161.74 MPa, less than the allowable stress 167.86 MPa.(3) The inherent frequency of the forging roll is 81.59 Hz, which is greater than the rated frequency of the motor at 41.7 Hz, and meets the design requirements.(4) The mass of the forging roll was regarded as the optimization objective, and the optimal values of six related parameters were calculated: plate thickness is 12 mm, column width is 68 mm, beam height is 116 mm, beam height is 132 mm, frame thickness is 222 mm, corner radius is 38 mm, the most cost-effective measure which improves the frame stiffness and strength is to increase the beam height.(5) It was found that the roll forging force increased with the increase of the forging speed by simulating the roll forging of 6061 aluminum. While the roll forging speed increased from 10r/min to 100 r/min, the forging force increased by around 25%, the forging torque increased by around 29%, and the power of roll forging increased by around 11 times.