Design of profile rolling processes – Partially automated, numerical design and extension of process limits with regard to output and shaping in profile rolling
The use of FEM significantly increases the cost and time efficiency of the design of forming processes. In the field of profile rolling, however, it is still only used to a very limited extent due to the challenging nature of the simulations. Within the scope of this project, a contribution was made to enable FEM simulations to predict process failures due to workpiece slippage in the future. Based on optical measurements in an industrial environment, the process limit could be comprehensively captured and characterized. By implementing a multidimensional friction model into the FEM, the simulation was enabled to predict the rolling behavior of the workpiece in a simulative way.
The development towards ever shorter product life cycles, with increasing component complexity, reinforces the need for lean, digital process design in the area of fasteners. Against this background, the transformation of process design, which has been strongly empirical and iterative up to now, to a knowledge-based and FEM-supported process design seems to be long overdue. For a future effective use of FEM in design processes, it must be able to predict typical rolling defects. In this research project, the mapping of one of the most common rolling defects – component slippage – is investigated using FEM. The use of FEM increases the time and cost efficiency of the design of profile rolling processes and enables the easy extension of the product portfolio of rolled components.
The solution pursued in the project can be divided into two parts. At the beginning, in the experimental part of the project, the slippage behavior was recorded by force measurements and optical slippage measurements in an industrial environment. Figure  shows the experimental tool used and the schematic structure of the optical measurement. The measurements show that the slipping behavior is strongly dependent on the tribological system and the strokerate. In the second part of the project, in which the FEM was used to model the slipping behavior, tribometer tests and simulations were carried out. During the tribometer tests, friction values were determined for the investigated tribological systems as a function of the tribological loads occurring in the contact zone. By integrating the multidimensional friction model derived from this, the FEM was able to predict the slipping behavior recorded in the experimental part of the project.
IGF project 20722N was funded by the Federal Ministry for Economic Affairs and Climate Action via the AiF as part of the program to promote joint industrial research and development (IGF) on the basis of a resolution of the German Bundestag. The long version of the final report can be requested from Forschungsgesellschaft Stahlverformung e.V., Goldene Pforte 1, 58093 Hagen, Germany.