径轴向轧制大型异形截面环件的有限元数值模拟研究.docx

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Abstract
In this paper, a finite element numerical simulation of the axial rolling of large-sized special section ring parts is conducted. The simulation takes into account the frictional and deformation characteristics of the material, as well as the influence of different process parameters on the final product. The results show that the deformation process is affected by many factors, such as the roll gap, the roll speed, and the geometry of the cross-section. The simulation results provide a useful basis for improving the quality and efficiency of the manufacturing process.
Introduction
Ring parts with special sections are widely used in engineering and industrial applications, such as gears, bearings, and heavy machinery. Due to their large size and complex geometries, these parts are typically manufactured using the method of axial rolling. In this process, the ring is formed by being passed through a series of rotating rollers, which compress the material into the desired shape.
The quality and efficiency of the production process depend on a range of factors, including the material properties, the machine design, and the process parameters. Numerical simulation is a valuable tool for analyzing these factors and optimizing the manufacturing process.
In this study, we conduct a finite element simulation of the axial rolling process for large-sized special section ring parts. The simulation takes into account the frictional and deformation characteristics of the material, as well as the effects of different process parameters on the final product.
Methodology
The finite element simulation is performed using ABAQUS software. The ring parts are modeled as three-dimensional solid objects, and the rolling rollers are modeled as rigid bodies. The simulation includes the following steps:
1. Material modeling: The material properties, such as Young’s modulus, yield strength, and Poisson’s ratio, are specified for the ring parts.
2. Geometric modeling: The geometry of the ring parts is specified, including the cross-section shape and dimensions.
3. Boundary conditions: The boundary conditions are specified, including the roller speeds, the roll gap, and the axial forces.
4. Rolling simulation: The rolling process is simulated using a series of incremental deformations. The frictional forces and the deformation characteristics of the material are taken into account.
5. Post-processing: The results of the simulation are analyzed, including the final geometry of the parts and the stress and strain distribution.
Results and Discussion
The simulation results show that the deformation process is affected by many factors, such as the roll gap, the roll speed, and the geometry of the cross-section. For example, increasing the roll gap can lead to greater deformation and thinner wall thickness. However, if the gap is too large, the deformation may become non-uniform and lead to defects in the final product. Similarly, increasing the roller speed can increase the deformation rate, but may also lead to higher levels of stress and strain.
The results also indicate that the material properties, such as the Young’s modulus and yield strength, have a significant impact on the deformation process. Materials with higher stiffness and strength require greater rolling forces, which can lead to higher levels of stress and strain. Therefore, it is important to select the appropriate material properties when designing the manufacturing process.
Conclusion
In conclusion, the finite element simulation of the axial rolling process for large-sized special section ring parts provides valuable insights into the deformation process and the influence of different process parameters. The simulation results can be used to optimize the manufacturing process and improve the quality and efficiency of production. Further research could involve experimental validation of the simulation results, as well as the development of more advanced numerical models that take into account additional factors, such as temperature and metallurgical properties.