Design of profile rolling processes

Semi-automated, numerical design and extension of the process limits with regard to output and shaping during profile rolling

Motivation

The advancing digitalization also affects more and more areas of value added in mechanical engineering. In cold forging, especially the use of the finite element method (FEM) in the design process holds a high potential due to the often complex process chains and high tool costs. While for many processes of cold forging the use of the FEM in the design process is already state of the art, the FEM simulation of profile rolling is limited to feasibility studies. Due to the extremely challenging friction and contact modelling, it currently has no comprehensive application in the industrial environment. The development of a verified and validated simulation model within the framework of the completed research project IGF 18395 N represents a first major step towards the use of the FEM in the design of profile rolling processes, which can increased in the project IGF 20722N.

Objective

The aim of the project is to improve the profile rolling process with regard to output and tool wear based on numerically obtained data. In addition to the tool optimization of already existing profile rolling processes, an extension of the product range as well as the use of the FEM simulation in the design process itself is aimed at in the long term.

Solution

At the beginning of the project, the FEM simulation will be used to identify the design optimization possibilities of the dies. Due to the considerable influence of the tribological system on the success of the profile rolling process, special attention will be paid to the tribological loads. Based on this knowledge, optimized dies are selected, manufactured and investigated concerning their performance in the industrial environment in cooperation with industrial project partners. In addition, the adapted tools are examined by confocal microscopy for their wear behavior using high-resolution polymer imprints. The combination of the knowledge gained forms the basis for the targeted rolling tool optimization regarding output and tool wear. The long-term goal of expanding the product spectrum of profile rolling and establishing the use of FEM simulation in process design will be pursued by further improving the friction modelling. Due to the strong inhomogeneity of the tribological loads over the contact surface, a more advanced friction model is implemented in the simulation with the help of subroutines. The friction coefficients required for this are determined with the help of the sliding compression test developed at the PtU.

Acknowledgements

The PtU would like to thank the AiF, the German Cold Forging Group (GCFG) and the participating companies for their support in implementing the IGF project no. 20722 N.