Erhöhung der Simulationsgenauigkeit von Profilwalzprozessen durch ein tiefgehendes Verständnis und eine realitätsnahe Beschreibung der Reibung

Increase of the accuracy of numerical simulations of profile rolling processes through an improvement of the process understanding an description of friction

 

Motivation

Profile rolling is a highly productive manufacturing process utilized to form circumferential grooves on cylindrical work pieces. This manufacturing process is often used to form threads. The design of processes used to form axisymmetric, customized grooves is mainly based on a trial and error approach. Especially the friction conditions in between work piece and tool have a significant influence towards the feasibility of the process. However, these friction conditions have not been systematically investigated as of today. Consequently, the design of new profile rolling processes is, due to this iterative character, cost- and time-intensive. The utilization of numerical simulation techniques promises to systematically improve the process design stage.

Aim

This research project aims at improving the design stage of customized profile rolling processes with the help of numerical simulations as well as the consideration of the tribology. The targeted investigation and modeling of friction promises to hold a significant potential to improving the design stage. According to the state of the art, the tribological loads as well as the linked friction conditions are unknown. Therefore, an empirical investigation of friction will be performed with the sliding compression test in order to create a data basis which aids the process design. The main objective is to develop an optimized numerical model that realistically maps the empirically determined friction conditions as well as friction values.

[1] Schematic illustration of profile rolling with flat dies (left) and an exemplary work piece (right)
[1] Schematic illustration of profile rolling with flat dies (left) and an exemplary work piece (right)

Approach

Next to the creation of suitable 2D- and 3D numerical models, the modeling of friction is of utmost importance. Friction is determined with the help of tribometer tests and is in turn modeled within the numerical models. Additionally, a test stand for profile rolling will be designed and built. With the help of this test stand it will be possible to verify and further develop and optimize the numerical simulations as well as improve the general process understanding.

Acknowledgement

The PtU would like to thank the Arbeitsgemeinschaft industrieller Forschungsvereinigungen “Otto von Guericke” e.V. (AiF), the German Cold Forging Group (GCFG) and the following companies for their support.

  • Arnold Umformtechnik GmbH & Co. KG
  • baier & michels GmbH & Co. KG
  • Cal Bechem GmbH
  • CIC – Concept Industrie Consult GmbH
  • EJOT Holding GmbH & Co. KG
  • EWMenn GmbH & Co. KG
  • KAMAX Automotive GmbH
  • Kistler Automotive GmbH
  • Kolb GmbH
  • MKU-Chemie GmbH
  • Presswerk Krefeld GmbH & Co. KG
  • Prinz Verbindungselemente GmbH
  • Simufact Engineering GmbH
  • SSF Verbindungsteile GmbH
  • Transvalor S.A.
  • Zwez-Chemie GmbH