CALCULATION METHODOLOGY FOR GEOMETRICAL CHARACTERISTICS OF THE FORMING TOOL FOR RIB COLD ROLLING

Andrej Olejnik; Alexey Kapitanov; Islam Alexandrov; Aslan Tatarkanov

doi:10.5937/jaes18-25211

Andrej Olejnik MSUT “STANKIN”
Alexey Kapitanov MSUT “STANKIN”, Russia, Moscow
Islam Alexandrov IDTI RAS, Russia, Moscow
Aslan Tatarkanov IDTI RAS, Russia, Moscow

DOI: https://doi.org/10.5937/jaes18-25211

Keywords: Ribbed surfaces, calculation methodology, forming tool, cold rolling, enveloping method

Abstract

Calculation of the forming tool for rib cold rolling by the enveloping method is usually complex and very time-consuming. The cold rolling process is not always optimized, resulting in a poor quality of the rolled rib profile and premature failure of the forming tool. Improvement in techniques of rib rolling on metal heat-exchange tubes is a challenging technological task which has defined the purpose of the present work – the study of the effect of the forming tool for cold rolling of ribs by enveloping method on the accuracy of geometrical dimensions of ribbed surfaces. Absence of a well-developed calculation methodology for this type of tool at the present time adversely affects the rate of manufacturing application of rib cold rolling processes. Since the main task when introducing the rib rolling process is to achieve the required accuracy of the workpiece, it seems expedient to improve calculation methodologies allowing to design a forming tool for rib cold rolling taking into account the required accuracy of geometrical dimensions of the ribbed surfaces. The present work proposes a methodology that allows you to perform calculations of parameters required for manufacturing and supervision over various rolling tools. Experimental approbation data of the outlined methodology results are presented. As a result of deformation processing without additional technological operations, the effect of surface hardening has been achieved, and the roughness of rolled ribbed surfaces R_a was 0.8 μm, which is comparable in quality only with finishing machining. It was demonstrated that when calculating the coordinates of profile points, the geometry of the lead-in, as well as rolls with a screw rib, it is particularly important to determine the angle of crush forming rolls and the y-coordinate of rolling bars as the main characteristics of the profile.

References

[1] Hakansson, H. (2015). Industrial Technological Development. Routledge Revivals, London. doi:10.4324/9781315724935.
[2] Acemoglu, D. (2012). Introduction to economic growth. Journal of Economic Theory, vol. 147, no. 2, 545–550. doi:10.1016/j.jet.2012.01.023.
[3] Olejnik, A.V. (2009). The tasks of intellectual development and support of innovative infrastructure in the Russian Federation. Scientific and Technical Information Processing, vol. 36, pp. 1, 39–42. doi:10.3103/s0147688209010055.
[4] Glazyev, S. (2018). Discovery of Regularities of Changes of Technological Orders in the Central Economic and Mathematics Institute of the Soviet Academy of Sciences. Economics and Mathematical Methods, vol. 3, 17–30. doi:10.31857/s042473880000655-9.
[5] Hitomi, K. (2017). Manufacturing Systems Engineering. Routledge, London. doi:10.1201/9780203748145.
[6] Agafonov, F., Genin, A., Kalinina, O., Brel, O., Zhironkina, O. (2017). Technological convergence and innovative development of natural resource economy. E3S Web of Conferences, vol. 15, 04011. doi:10.1051/e3sconf/20171504011.
[7] Zheng, D. (2015). Industrial Engineering and Manufacturing Technology. Proceedings of the 2014 International Conference on Industrial Engineering and Manufacturing Technology (ICIEMT 2014), July 10-11, 2014, Shanghai, China. doi:10.1201/b18144.
[8] Semenov, A.B., Fomina, O.N., Muranov, A.N., Kutsbakh, A.A., Semenov, B.I. (2019). The Modern Market of Blank Productions in Mechanical Engineering and the Problem of Standardization of New Materials and Technological Processes. Advanced Materials & Technologies, vol. 1, 003–011. doi:10.17277/amt.2019.01.pp.003-011.
[9] Semenov, A.B., Kutsbakh, A.A., Muranov, A.N., Semenov, B.I. (2019). Metallurgy of thixotropic materials: the experience of organizing the processing of structural materials in engineering Thixo and MIM methods. IOP Conference Series: Materials Science and Engineering, vol. 683, 012056. doi:10.1088/1757-899x/683/1/012056.
[10] Jiang, Z.Y. (2011). Mechanics of cold rolling of thin strip. Numerical analysis–Theory and application, IntechOpen, Rijeka, 439-462. doi:10.5772/23344.
[11] Gubanova, N.V., Karelin, F.R., Choporov, V.F., Yusupov, V.S. (2011). Study of rolling in helical rolls by mathematical simulation with the DEFORM 3D software package. Russian Metallurgy (Metally), vol. 2011, no. 3, 188–193. doi:10.1134/s0036029511030074.
[12] Fedorov, S.V., Aleshin, S.V., Swe, M.H., Abdirova, R.D., Kapitanov, A.V., Egorov, S.B. (2017). Comprehensive surface treatment of high-speed steel tool. Mechanics & Industry, vol. 18, no. 7, 711. doi:10.1051/meca/2017066.
[13] Johnson, K.L. (2000). Plastic Deformation in Rolling Contact. Rolling Contact Phenomena, 163–201. doi:10.1007/978-3-7091-2782-7_3.
[14] Bower, A.F., Johnson, K.L. (1989). The influence of strain hardening on cumulative plastic deformation in rolling and sliding line contact. Journal of the Mechanics and Physics of Solids, vol. 37, no. 4, 471–493. doi:10.1016/0022-5096(89)90025-2.
[15] McDowell, D.L., Moyar, G.J. (1990). Effects of non-linear kinematic hardening on plastic deformation and residual stresses in rolling line contact. Mechanics and Fatigue in Wheel/Rail Contact, 19–37. doi:10.1016/b978-0-444-88774-0.50006-7.
[16] Yoshimi, T., Matsumoto, S., Tozaki, Y., Yoshida, T., Sonobe, H., Nishide, T. (2009). Work Hardening and Change in Contact Condition of Rolling Contact Surface with Plastic Deformation. Tribology Online, vol. 4, no. 1, 1–5. doi:10.2474/trol.4.1.
[17] Wais, P. (2012). Fin-Tube Heat Exchanger Optimization. Heat Exchangers - Basics Design Applications. InTech, Rijeka. doi:10.5772/33492.
[18] Wang, F., Liang, C., Yang, M., Fan, C., Zhang, X. (2015). Effects of surface characteristic on frosting and defrosting behaviors of fin-tube heat exchangers. Applied Thermal Engineering, vol. 75, 1126–1132. doi:10.1016/j.applthermaleng.2014.10.090.
[19] Čarija, Z., Franković, B., Perčić, M., Čavrak, M. (2014). Heat transfer analysis of fin-and-tube heat exchangers with flat and louvered fin geometries. International Journal of Refrigeration, vol. 45, 160–167. doi:10.1016/j.ijrefrig.2014.05.026.
[20] Kim, K., Lee, K.-S. (2013). Frosting and defrosting characteristics of surface-treated louvered-fin heat exchangers: Effects of fin pitch and experimental conditions. International Journal of Heat and Mass Transfer, vol. 60, 505–511. doi:10.1016/j.ijheatmasstransfer.2013.01.036.
[21] Li, Z. (2018). Elastic Deformation of Surface Topography under Line Contact and Sliding-rolling Conditions. Journal of Mechanical Engineering, vol. 54, no. 5, 142. doi:10.3901/jme.2018.05.142.
[22] Jiang, Z., Xie, H. (2018). Application of Finite Element Analysis in Multiscale Metal Forming Process. Finite Element Method - Simulation, Numerical Analysis and Solution Techniques. InTech, Rijeka. doi:10.5772/intechopen.71880.
[23] Hong-SeokPark, Tran Viet, Anh. (2010). Finite Element Analysis of roll forming process of aluminum automotive component. International Forum on Strategic Technology 2010. doi:10.1109/ifost.2010.5667921.
[24] Hao, L., Jiang, Z., Wei, D., & Chen, X. (2013). Finite element analysis of roll bit behaviors in cold foil rolling process. AIP Conference Proceedings, vol. 1532, 478. doi:10.1063/1.4806864.
[25] Jung, D.W. (2018). Finite Element Analysis for the Roll Forming Process of Rib. Applied Mechanics and Materials, vol. 878, 302–307. doi:10.4028/www.scientific.net/amm.878.302.
[26] Tsang, K.S., Ion, W., Blackwell, P., English, M. (2017). Validation of a finite element model of the cold roll forming process on the basis of 3D geometric accuracy. Procedia Engineering, vol. 207, 1278–1283. doi:10.1016/j.proeng.2017.10.883.
[27] Strycharska, D., Szota, P., Mróz, S. (2017). Increasing the Durability of Separating Rolls during Rolling Ribbed Bars in the Three-Strand Technology. Archives of Metallurgy and Materials, vol. 62, no. 3, 1535–1540. doi:10.1515/amm-2017-0236.
[28] Szota, P., Strycharska, D., Mróz, S., Stefanik, A. (2015). Analysis of Rolls Wear during the Ribbed Bars Multi-Slit Rolling Process. Archives of Metallurgy and Materials, vol. 60, no. 2, 815–820. doi:10.1515/amm-2015-0212.
[29] Strycharska, D. (2019). Analysis of Roll Wear Costs During Multi-Strand Rolling of Ribbed Bars Using New Slitting Pass System. New Trends in Production Engineering, vol. 2, no. 2, 267–278. doi:10.2478/ntpe-2019-0091.
[30] Kar’kina, L.E., Zubkova, T.A., Yakovleva, I.L. (2013). Dislocation structure of cementite in granular pearlite after cold plastic deformation. The Physics of Metals and Metallography, vol. 114, no. 3, 234–241. doi:10.1134/s0031918x13030095.
[31] Yakovleva, I.L., Kar’kina, L.E., Zubkova, T.A., Tabatchikova, T.I. (2011). Effect of cold plastic deformation on the structure of granular pearlite in carbon steels. The Physics of Metals and Metallography, vol. 112, no. 1, 101–108. doi:10.1134/s0031918x11010388.
[32] Qiao, X.G., Gao, N., Starink, M.J. (2012). A model of grain refinement and strengthening of Al alloys due to cold severe plastic deformation. Philosophical Magazine, vol. 92, no. 4, 446–470. doi:10.1080/14786435.2011.616865.