Prsentation PowerPoint
Industrialization of Cross Wedge RollingEric FREMEAUX1, Catalina
GUTIERREZ2, Laurent LANGLOIS2, Philippe MANGIN2, Rgis BIGOT2,
Pierre KRUMPIPE3, Valery SHCHUKIN4
With the technical and scientific support of: IWU Chemnitz,
Dr-Ing Hab. Bernd LORENZ
1Ateliers des Janves, Avenue des marguerittes, 08120
Bogny-sur-Meuse, France2ENSAM, 4 rue Augustin Fresnel, 57070 Metz,
France3CETIM, 7 rue de la Presse, 50802 Saint-Etienne cedex 1,
France4Physical Technical Institute, 10 Kuprevich Street, 220141
Linsk, Belarus
NNSummaryIntroductionCWR principleAdvantages and
disadvantagesObjectives
CWR tool designDesign rulesApplication
To increase CWR Tool LifeIdentification of the limiting
phenomenonExperimental numerical investigation
Conclusion and future evolution
NNIntroductionThe two main configurations industrially developed
are: (A) flat type and (B) two roll type [Li, et al., 2008].
Flat wedge type
Two-roll typeCWR is a metal forming process in which a
cylindrical billet is plastically deformed into another
axisymmetrical shape by the action of wedge segments.
CWR Facilitiesat Ateliers Des Janves
NNCross wedge rolling
Double-diameter reduction.CWR tool with 2 wedges.Rolled parts
can be of simple diameter reduction or of several reductions.
Five-diameter reductionsCWR tool with 5 wedges
Simple diameter reduction.CWR tool with 1 wedge. [PATER
2010]
NNAdvantages and disadvantagesBenefits [Li and Lovell 2002] [Li
and Lovell 2008]Material and energy saving process with lower
environmental impact.Higher productivity (cycle time up to 5 10
sec).High accuracy and maximum proximity to required dimensions of
finished products.Difficulties [Weronski and Pater 1992]:Process
with a high degree of technological complexityNumber of parameters
affecting the stability of the process. Relationship between the
parameters that must be correctly chosen in order to avoid
failures.Slight variations in basic parameters can have a high
impact on the rolled part. CWR tool design has been based on the
experience and intuition of designers. No decision-making tools
publicly available to the date.Tool manufacturing and development
cost
Cross Wedge RollingForging RollingNNce qui rend le procd
intressant du point de vue environnemental.Gain notoire en termes
de mise au mille
5
Introduction
Application
Preform: Hot forging of connecting rodRobotized forging
workcellHammer
Productivity150% higher / Classical lineQuality: number of scrap
parts / 2Material saving (5%-15%)NNObjectivesIn order to increase
the performances of CWR
To reduce the developing time and cost of new CWR tool
To reduce the experimental part of the tool developmentTo
automate as far as possible the tool design methodology
To improve the life of the CWR tools
To increase the life of CWR (Number of parts manufactured per
tool)To stabilize the tool behavior To reduce the dispersion of the
tool lifeTo reduce the number of defect types limiting the tool
life NNSummaryIntroductionCWR principleAdvantages and
disadvantagesObjectives
CWR tool designDesign rulesApplication
To increase CWR Tool LifeIdentification of the limiting
phenomenonExperimental numerical investigation
Conclusion and future evolution
NN
Diagram of a wedge configuration [PATER 2003] CWR Tool
Design
CpCgCeCc 02 01 02 03YpLexxyyzzProfil 01Profil 02Profil 03 03
01Geometrical parameters of die configurationParameters of die
configuration- Identification of the tool design parameter
It is based on the parametric definition of the desired rolled
part and on the parametric definition of the tool.
NNCross wedge rolling tool design procedure COLT
Design rulesIntegrate the state of art and expertise as far as
possible
Design rules found in literature and identified during
experimental work.Design rules are associated with stability
indexFlexible tool by allowing updating of the already existing
rules and the implementation of new design rules;
[Fu and Dean 1992] Risk of central porosity [Fu and Dean 1992]
NeckingStability Index:
Associated with design parameters or function of design
parameters
Associated with each defectNNWhen inputting the geometric
characteristics of the desired rolled part we obtain the geometic
characteristics of the tool 10Cross wedge rolling tool design
procedure COLT
Output:Geometrical parameters of the CWR toolCoordinates of
remarkable points for flat type and/or two-roll typeStability
Indexes (potential defects)
.txt file with coordinates of remarkable pointsNNCross wedge
rolling tool design procedure COLT A decision supporting
methodology for the designing of the tool in CWR is being
developed.Solution provided by COLT is not expected to be
immediately efficient but as close as possible to a performant
solution. Synthesis of literature and experimental rules.The
designing rules allow the selection of basic parameters.An
stability index is introduced to take into account the
inconsistencies in literature.The advantages of the methodology
are:Non-expert user will have a first guided approach to the CWR
process.Identification of the potential defects with the associated
basic parameters.Flexibility of the methodology by the updating of
exiting rules and implementation of new ones.ConclusionsBenefitsNNA
decision supporting methodology for the designing of the tool in
CWR is being developed.It is based on a synthesis of literature and
experimental rules.The designing rules allow the selection of basic
parameters.An stability index is introduced to take into account
the inconsistencies in literature
The advantages of the methodology are:Reliability on scientific
and experimental bases.Relationship between the parameters at all
time during the COLT procedure. This allows to observe the
interaction and effects of the designing decisionsFlexibility of
the methodology. An user can obtain different wedges by modifying
one parameter.
Interactive method. The bibliographical and experimental
references as well as it maturity can be modified, eliminated or
even adding new sources.
12SummaryIntroductionCWR principleAdvantages and
disadvantagesObjectives
CWR tool designDesign rulesApplication
To increase CWR Tool LifeIdentification of the limiting
phenomenonExperimental numerical investigation
Conclusion and future evolution
NNTool Life in CWR are limited by geometrical defects of the
rolled partThe forged part doesnt meet its requirementsDefects
Dimension
The shape of the rolled part cannot be hot forged
Common defects on CWR products [Li and Lovell 2002]CWR Tool
Life
Spiral groove and striationCenter cracking
NMethodologyIdentification of the statistical correlations
between:Geometrical, kinematical, thermo mechanical
parametersandLimiting phenomenon
Initial value and evolution of the parameters along the tool
lifeRelative initial position of the different parts constituting
the toolsDifferential Kinematics of the toolsEvolution of the shape
of the tool due to wearDistribution of the temperature at the
surface of the toolCWR Tool LifeNSynchronism of two-roll tool
during rollingHigh speed cameraSchema installation
recorded image by the high speed camera
Synchronism of the grooves passing through a fixed frame was
studied.An analysis of the average angular velocity was calculated
by measuring the time between two grooves through the fixed
frame.CWR Tool LifeN
Evolution of tool wear Non-contact 3D measurement methods
Computer stereo vision
Relative position of the different parts of the toolEvolution of
the geometry due to wearCWR Tool LifeNConclusions and
perspectives
1- Experimental and statistical identification of the
correlation between tool and process parameters and the phenomenon
limiting tool life
2- Experimental and modelling-simulation investigation
Statistical relation Qualitative Quantitative Physical
relation
3- To design and to implement solutions in order to increase and
better control the life cycle of the CWR tool.
4- Integration of the result as knowledge withn the tool design
methodologyNew design rulesNew process parameters
CWR Tool LifeNIndustrial Academic PartnershipENSAM CETIMState of
the artIdentification of the key parametersInitial version of the
design methodology (Formalization of the know-how)
Scientific et technological support of PTI and IWUFinancial
support of Region LorraineAteliers des JanvesInvestmentIndustrial
implementation of the CWRKnow-how and experience
Skill- Knowledge management- Process thermo mechanical
simulation- Measurement and control of
manufacturingprocessIndustrial requirementKnow-howIndustrial
facilitiesFruitfull collaborationIncrease of the skill based on
scientific and technological approachIntegration of the skill as
computer aid tool for the industrialization of the process
NThank you for your attention
N