STUDY OF PARAMETRIC DESIGN IN DOUBLE-WEDGE CROSS WEDGE ROLLING MODELING. Associate Prof. Xing Xidong, PhD.

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1 STUDY OF PARAMETRIC DESIGN IN DOUBLE-WEDGE CROSS WEDGE ROLLING MODELING Associate Prof. Xing Xidong, PhD. Institute of Electrical Engineering, Chinese Academy of Science Laboratory of Solar Thermal Power P.O. Box2703, Beiertiao Zhongguancun, Beijing China, Abstract In Finite Element Analysis (FEA) of Double- Cross Wedge Rolling (DCWR), DCWR modeling by parameters is very important. With the help of software Pro/Engineer 2001, the source program to set up parametric DCWR model is devised in CWR modeling. As an example, the modeling technology of one step-shaft part is studied in particular. By finite element simulation and real rolling experiment, this method is proved to be correct and highly efficient. It can provide better precondition for designing DCWR mould by parameters and finite element simulation. Key words Cross rolling double- Finite element simulation 1 INTRODUCTION Double- Cross rolling (DCWR), is a new metal forming process in which a cylindrical billet is plastically deformed into an long axial parts with many steps by the rotating double- mould, fig.1 shows the mechanism of DCWR. Rollers with two -shaped dies move counter-rotating, and the billet suffers complex deformation, including compression in radial direction, elongation in axial direction and circumferential flow, during its rotation among the rotation dies. Fig.1 Principle of Double- Cross rolling DCWR possesses many advantages over the single- Cross rolling (CWR), such as more productivity, less equipment weight and circumference of rolls in making some long and multi-step components. Normally DCWR can produce parts which are times longer than those made by conventional CWR on the same machine. Since CWR has been invented by JiriHolub in Czechoslovakia in 1960s, many researchers from many countries have investigated into its forming mechanism, die designing, technology parameters 1

2 and processing defect with many method, and Finite Element Method (FEM) has been used in CWR investigation for over 20 years. However, many operations are needed to be finished in FEM, such as modeling, computation, and so on. Setting up the model before calculation costs lots of time, any FEM project needs this routine to be finished, however none open literatures on CWR investigated into the modeling technology in detail. Minting Wang et al. simply presented a coupled thermal, mechanical, and microstructure simulation model for the CWR process with the help of Solidworks 2000 and Visual Basic 6.0. In this paper, in order to quicken the modeling speed in DCWR, the modeling method by Pro/E 2001 is introduced and investigated at length, taking one step-shaft part as example, a new and innovative numerical model in DCWR was developed, basing on the new concept of parameterization, basing on the feature, whole relation in Pro/Engineer, and the modeling process in this part is investigated in detail. The whole MCWR process was simulated successfully. Experimental studies were conducted in order to validate the FEM model and its result. All of the above presented shall make its tremendous popularity in modeling by Pro/ENGINEER in the metal manufacturing industry, and serves as a DCWR guideline in selecting the DCWR tool parameters in reason. 2 BRIEF INTRODUCTION OF PRO/ENGINEER Pro/engineer was developed by Parametric Technology Corporation, USA, as one of most widely used 3D product design solution around the world; its standard in 3D product design features promotes best practices in design while ensuring compliance with any industry and company standards. Integrated Pro/ENGINEER CAD/CAM/CAE solutions allow any users to design faster than ever, while maximizing innovation and quality to ultimately create exceptional products. It has been widely used in electric, machine, industry design, automobile, and so on, with the integration of part design, model development, numerical control manufacturing, industry design, reverse engineering, etc. Its main virtues are as the following: 1) All parameterization and automatic propagation of design made the part design and modification very convenient. 2) Data from the design and manufacturing can be updated in time, now that only one database is adopted in Pro/Engineer, the feature of all relation made the modification in one model reflected in the other relative operation or models at once.3) The solid modeling basing on the feature made the consistency of software design with the engineers thought, and allowed for maximum designing efficiency. Due to the DCWR d die s diversities, a set of troublesome processes occur in the design process in DCWR modeling. Based on the above character of Pro/ENGINEER, the development of parameterized designed programs was conceived; it made this DCWR dies design efficient and convenient. Once the model is devised with the format of IGES, it can be exported to ANSYS in finite element simulation and analysis. 3 PARAMETERIZED MODELING Now that the plane of two- CWR roller is three-dimensional surface, it is very difficult in setting up models by Finite Element Method (FEM). However, ANSYS provided the implanted IGES filter, and the solid model can be devised with the help of PRO/ENGINEER by the format of IGES, so this model can be inputted into ANSYS. 2

3 In DCWR, all the feature of dies, reflecting the formed workpiece, such as the types, angles, lengths and so on, is parameterized and the optimized selection of the key factors in CWR process has been accomplished. All parameters inputted are listed in table 1. In order to quicken the modelling assignment, the general source program of all parameterization under area reduction ψ=50%, spreading angle β=8º, forming angle α=28º, and the length of original billet 576 mm, is written and shown under table 1, then embedded in Pro/Engineer It is suitable for the two- CWR model designing. Once these parameters are evaluated to new values and regeneration is executed, the new model is setup successfully. Table 1 Parameters in roller modeling symbol Items symbol items ALFA The forming angle BATA spreading angle FIV Part area reduction DIAMETE R Roller diameter THETA The relative rotating angle from the main to the second LENGTH The circumference length of die WIDTH Half width of roller THICK Roller thickness BATA1 Spreading angle in the main W1 Half of the spreading width in the main XGAO1 Height of the main HH1 The knifing length in the main BB1 Distance from second to the main Rotating angle in the main THETA11 THETA12 Rotating angle in the second BATA2 Spreading angle in the second XGAO2 The height of second W2 The width of the second DGAO1 The height of fillet in main ANGLE10 The cutting angle degree in main GAO2 The height in the second cutting ANGLE2 Cutting angle in the second ROTATE1 The bending angle of two s LENGTH1 The model length in the coordinates ALFA=28 BATA=8 FIV=0.5 THETA=4.02 DIAMETER=576 /*STEP-1 LENGTH=706.5 LENGTH1=LENGTH/2 /* half in length in the coordinate WIDTH=245 THICK=38 /*STEP-2 3

BATA1=BATA W1=61.02 XGAO1=5+(40-40*SQRT(1-FIV))/2 /*STEP-3 HH1=105.94 BB1=61.02 THETA11=THETA THETA12=THETA BATA2=BATA+THETA XGAO2=XGAO1 W2=61.

4 BATA1=BATA W1=61.02 XGAO1=5+(40-40*SQRT(1-FIV))/2 /*STEP-3 HH1= BB1=61.02 THETA11=THETA THETA12=THETA BATA2=BATA+THETA XGAO2=XGAO1 W2=61.06 DGAO1=XGAO1 ALFA1=ATAN(TAN(ALFA)/COS(BATA)) ANGLE10=90-ALFA1 GAO2=XGAO2 ALFA2=ATAN(TAN(ALFA)/COS(BATA)) ANGLE2=90-ALFA2 XGAO3=XGAO2 ANGLE3=20 /*STEP-1 the cutting angle in the right of the second ROTATE1=LENGTH*360/(PI*DIAMETER) /*STEP the bending angle of both s The modelling process is as follows: Firstly both the datum coordinate systems and the datum planes are setup, the base features are setup (the base are made, then the main and the second are to be added on it), then the rectangle is setup, with width (refers to roller circumference spreading length) mm, and the Fig.2 The FEA model of DCWR height 245 mm, it is also called axial manufacturing dimension of part. Afterwards, this rectangle is executed the extrude operation with the thickness 38 mm, accords with the model in thickness in the experiment. Then the main and the second is drawn on the base features and cut off with the ANGLE10 and ANGLE2, shown in table1. Finally, the base and the main, the second are rotated with the angle ROTATE1, shown in table 1. Half of the double- CWR roller and workpiece is formed and shown in fig.2, and the real workpiece under the above condition was manufactured by this dies are shown in fig. 3. Fig. 3 The specimen by parametric mould 4 FEM SIMULATION AND EXPERIMENTAL VERIFICATION Finite element simulation is composed of 3 steps: firstly pre-processing, then calculation, at last post-processing. The main routine in step 1 is as the following, the basic assumption is adopted, and 4

5 the processing parameters, such as spreading angle, forming angle and area reduction, etc, are defined, the billet is φ40mm(d0), material of workpiece is AISI Parameters of material both in roller and workpiece are shown in table 2, fig. 4 shows the relation of stress with strain of AISI 1045 at The complete model, already shown in fig. 2 is set-up by the Pro/Engineer, then inputted into LS-DYNA, boundary conditions on both rollers and work piece are defined. The *.k file after pre-processing is formed, and then it is solved by the LS/DYNA solver. Table 2 parameter of material content Modulus of elasticity E/Mpa Poisson ratio µ Density /kg/mm3 roller Work piece After solving, rolling force can be obtained and shown in Fig.4. Fig. 4 the FEM and testing results Rolling Force/KN % Rolling Force FEM result inspecting result ,000 1,200 tool length/mm Under the condition of area reduction ψ=40%, spreading angle β=6º, forming angle α=30º, the length of original billet 260 mm, and heating centigrade 1100 (before deforming), the testing result and the FEM one are shown in fig. 4, the FEM result of the maximum rolling force is in agreement with one of the testing result, with the error of less than 5%, which demonstrates the veracity and reliability in double- cross rolling modeling. 5 CONCLUSIONS With the help of Pro/ENGINEER 2001, the parameterized die designing program for DCWR has been developed, which can determine optimally the key factors in DCWR processing. FEM simulation and experiment were carried out afterward. With experimental verification, this modeling technology can provide one good tool in DCWR modeling. 5

6 ACKNOWLEDGEMENT This research is support by National Natural Science Foundation of China (No ) REFERENCES Hu Zhenghuan. K. S. Zhang, B. Y. Wang, and W. Zhang, 1996,Theory and Application of Cross Wedge Rolling, Metall. Industry Press, Beijing, China. Minting wang, et al, 2005, A coupled thermal-mechanical and microstructural simulation of the cross rolling process and experimental verification [J], Material Science and Engineering A 391, Xing xidong, 2006, Mechanism investigation s of Multi- Cross Wedge Rolling, PhD dissertation, University of Science and Technology, advisor: Hu Zhenghuan & Shu Xuedao. Yaomin Dong, Kaveh Tagavi, Michael Lovell, et al, 2000, Analysis of stress in cross rolling with application to failure [J]. International Journal of Mechanical Science 42, Zb. Pater, 1999, Numerical simulation of the cross- rolling process including upsetting, J. Mater. Process. Technology 92-93,

Analysis of Crank End of Connecting Rod using Finite Element Method

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