A. Tofil

FEM SIMULATION OF THE TUBE ROLLING PROCESS IN DIESCHER'S MILL

This paper deals with the issue of numerical modelling of the piercing process of a thick–walled bush in a two-rolled skew rolling mill, equipped with guiding devices of Diescher’s type. After a short characteristic of the subject matter, the developed geometric model of the process was discussed, with taking kinematics of tools movement and thermal phenomena present in metal during forming into consideration. Next, the results of calculations were presented in a form of fields of strain, damage criterion and temperature. Distributions of force parameters acting on particular tools during the process of bush rolling were also given.

Overview of the research on roll forging processes

The paper overviews the research on roll forging processes in the last two decades. Given the broad scope of this problem, the overview focuses on processes in forging plants, omitting those performed in metallurgical plants. Three rolling processes are discussed in detail: longitudinal rolling, cross rolling and helical rolling. Each of the three techniques is discussed in terms of the main research problems and potential directions of future development.

Comparative Analysis of Forging Rolling and Cross-Wedge Rolling of Forgings from Titanium Alloy Ti6Al4V

Theoretical-experimental results of forging rolling and cross-wedge rolling of stepped shafts forgings from titanium alloy Ti6Al4V are presented in this paper. Theoretical assumptions were based on the results of numerical simulations conducted by means of finite element method with the application of software Simufact Forming. During numerical simulations optimal parameters of the rolling processes were determined in view to possibility of obtaining forgings of assumed quality and stable process course. Experimental verification was conducted in universal forging rolling mill of own design, which allows for realization of such processes as splitting without waste, forging rolling and cross as well as cross-wedge rolling processes. During conducted research influence of the way of rolling on the obtained parts quality and the process force parameters were determined. Complex analysis of the chosen rolling parameters impact on the rolling process course and quality of finished products was made. Conducted research showed that it is possible to roll axi-symmetrical forgings of stepped shafts both in transverse and longitudinal arrangement. However, forgings rolled crosswise are characterized by larger precision than in comparison with semi-finished products in longitudinal arrangement.

Manufacturing process of plane rim from aluminium alloy

Purpose – The purpose of research was to work out manufacturing technology of plane rim from 2618A aluminium alloy based on hammer forging process. Design/methodology/approach – It was assumed that the manufacturing process consists of die hammer forging and machining. The first stage of the research works was based on designing of the forging process and on numerical simulations in which finite element method was used. On the basis of calculations results, analysis of deformation parameters in the drop forging was made and the rightness of the worked out technology was verified. The second stage of the research works concerned experiments conducted in industrial conditions. Forging dies were constructed and the forging process of a series of drop forgings was carried out. Next machining was done to obtain finished parts. Findings – The conducted research works on the forging process on hammer of the rim drop forging from 2618A aluminium alloy showed that the application of this technology allows for obta...

NUMERICAL ANALYSIS OF SPLITTING WITHOUT WASTE BASED ON CROSS-WEDGE ROLLING IN DOUBLE ROLLING MECHANISM

The article presents the results of numerical analysis of splitting without waste on the basis of cross wedge rolling in double rolling mechanism. The analysed process concerns rolling the charge of V-shaped groove, and rotary bending causing the split of the material. In the calculations a method of finite elements (FEM) was used. The obtained results allowed detailed analysis of the splitting process in terms of the level of deformation, strains, material breaking, flow kinematics and strength parameters.