simulation ring rolling process account …©s/complas 2013... · complas xii, international...

1 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona

SIMULATION OF THE RING ROLLING PROCESS TAKING INTO

ACCOUNT AUTOMATIC MOTION CONTROL

-

PREDICTION OF MICROSTRUCTURE

PATRICE LASNE, AMICO SETTEFRATI, MICKAEL BARBELET


CONTEXT

INTRODUCTION TO RING ROLLING PILOTING

INDUSTRIAL EXAMPLE OF A SHAPED RING

RECRYSTALLIZATION DURING RING ROLLING

PERSPECTIVES & CONCLUSIONS

OVERVIEW


CONTEXT





OVERVIEW


CONTEXT

Ring-rolling is a complex incremental process Large number of revolutions

Small area of contact

Number of works have been done to improve simulation of the

Ring-Rolling Process Optimum Meshing

Parallel computing

ALE Formulation

Automatic Centering

Contact smoothing method

…


CONTEXT





OVERVIEW


RING ROLLING PILOTING

Conical

Rolls

King-Roll

Centering-Rolls Mandrel


RING-ROLLING PILOTING

h Ring height

with FORGE : use of ‘automatic centering’ option

to avoid centering rolls piloting

Ring thickness

s

D Ring Outer Diameter


SIMPLE EXAMPLE OF PILOTING

Industrial ring rolling mill piloting data :

Mandrel velocity : Vmandrel = f(Dring)

Ring height : Hring = f(Dring)

Rotation speed for the king roll : constant

Rotation speed for the mandrel & axial conical rolls : automatic rotation


SIMPLE EXAMPLE OF PILOTING


CONTEXT


INDUSTRIAL EXAMPLE OF RING-SHAPED PROFILE



OVERVIEW


INDUSTRIAL EXAMPLE – SHAPED RING

Material description : Inconel 718

Elasto-plastic behaviour :

JmatPro (Sente-Software) data :

thpe

eeee Itracedt

d

2 ,...,,00 Tpp



Initial bulk forging sequence:

Upsetting Preforming Piercing


INDUSTRIAL EXAMPLE – SHAPED RING Conical

Roll

King-Roll

Mandrel

Laser measurement



Laser measurement h Ring height

D Ring Outer Diameter

Ring thickness

s


INDUSTRIAL EXAMPLE – SHAPED RING Industrial ring rolling mill piloting data :

Ring Growth Speed :

Ring Height : Hring = f(Tring)

Rotation speed for the king roll : constant

Rotation speed for the mandrel & axial conical roll : automatic rotation

)( ring

ringDf

dt

dD


CONTEXT





OVERVIEW


RECRYSTALLIZATION DURING RING-ROLLING



Recrystallization model

Dynamic Recrystallysation

Post-Dynamic Recrystallization :

Grain Growth :

drxn

c

cdrxX

5.0

).2ln(exp1),,(

.

02 Tdfdwith

Xdd

d

adrx

drxddrx

pdrx

pdrx

n

pdrxt

tX

5,0

).2ln(exp1),,,(

.

04 Tdfdwith

Xdd

p

apdrx

pdrxppdrx

tRT

QGdd

Ggr

g

GgGg

gg .exp2

1

0

1


RECRYSTALLIZATION DURING RING-ROLLING 3 Population of grains

Dynamic recrystallized

Meta-dynamic recrystallized

Non recrystallized


RECRYSTALLIZATION DURING RING-ROLLING Grain size evolution



Non recrystallized


CONTEXT





OVERVIEW


A more complete piloting approach to avoid current limitations

We do not take into account ring mill limitations (force, torque)

The automatic centering option may not be “100% perfect”

It is very difficult to have feedback about the piloting of industrial ring mills

Black box :

A lot of input parameters can be used as input :

Ring measurements (D, s, h, …)

Velocities / Rotation speeds

Forces / Torques

…

Output :

Imposed velocities / Imposed rotation speeds

Imposed forces / Imposed torques

…



Solutions Increase know-how based on collaborative work with ring rolling mill manufacturers

Open Forge software to allow the definition of complex piloting

(e.g. External module for User Piloting)


shD

F

V

,,

,

,

External

User

Piloting

At each

increment

...

,

,

impimp

impimp

F

V


THANK YOU

FOR YOUR ATTENTION

ADDRESS: 694, av du Dr. Maurice Donat

Parc de Haute Technologie

06255 Mougins cedex

France

CONTACT: +33 (0)4 9292 4218

+33 (0)4 9292 4201

[email protected]

http://www.transvalor.com/

simulation ring rolling process account …©s/complas 2013... · complas xii, international...

Documents