Research On Stable Rolling Technology Of Large Diameter/Thickness Ratio Disc By Double Roll Rotary Forging

Twin-roll rotary forging is a kind of rotational plastic processing technology in which the symmetrical roll rotates around the axis of the machine tool spindle and rotates around its axis.At the same time,when the lower die is fed,the large diameter/thickness ratio disc is continuously rolled by twin roll,resulting in deformation.It has many advantages such as labor saving,energy saving,Less material waste,low working noise,good product quality and low-cost.Therefore,the large diameter/thickness ratio disc has been widely used in many industrial fields such as deep-sea exploration,machine tools,electrical appliances,aerospace and so on.It has become the advanced manufacturing technology and main processing method of disc,ring,flange and various gear parts.Due to the lack of systematic and in-depth research,the large diameter/thickness ratio of rotary forging is faced with technical difficulties such as theoretical calculation analysis and optimization design of forming process.Therefore,it is a very important subject in the development of rotary forging technology to study the technological conditions and process parameters optimization of large diameter/thickness ratio disc stable rolling with twin rolls.In this paper,the forming process of twin-roll rotary forging disc with large diameter/thickness ratio is systematically studied by using finite element simulation technology and physical experiment.The contents and achievements about research on stable rolling technology of large diameter/thickness ratio disc by double roll rotary forging are as follows:Based on the basic principle of twin-roll rotary forging and the basic theories of mathematics,physics,plastic mechanics and metal plastic forming,the distribution of plastic deformation zone was studied.The formulas for calculating the forming force,torque,energy and work of twin-roll rotary forging were obtained.The stable rolling conditions of twin-roll rotary forging disc were deduced.The accuracy of stable rolling conditions and calculation of force and energy parameters were verified by twin-roll rotary forging equipment.Through the die structure of twin-roll rotary forging disc with large diameter/thickness ratio,the movement mode of twin-roll rotary forging disc was analyzed,the three-dimensional finite element model of large diameter disc was established,and the key conditions of numerical simulation were accurately processed.Based on DEFORM-3D numerical simulation analysis software,the plastic deformation process was simulated and analyzed.The deformation characteristics and evolution law of large diameter/thickness ratio disc parts by twin-roll rotary forging were described in detail.Based on the three-dimensional finite element simulation model of twin-roll rotary forging disc with large diameter/thickness ratio,the effects of various process parameters(initial billet temperature,feed speed of lower die,roll speed,friction coefficient,etc.)on metal flow and stress-strain of the large diameter/thickness ratio disc,force-energy parameters of twin roll rotary forging machine in the large diameter/thickness ratio disc forming process were studied.The research results fully reveal the deformation mechanism of twin-roll rotary forging,and provide an important theoretical basis for optimizing process parameters and accurately controlling the large diameter/thickness ratio of twin-roll rotary forging.Taking 45# steel as materials,the deformation law of large diameter/thickness ratio disc formed by twin-roll rotary forging was studied and the technological parameters affecting the forming of large diameter disc by twin-roll rotary forging were analyzed,which provided a reference for future numerical simulation of rotary forging.