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Research Papers

3D FE Modeling Simulation for Wear in Cold Rotary Forging of 20CrMnTi Alloy

[+] Author and Article Information
Xinghui Han

e-mail: hanxinghuihlp@126.com

Lin Hua

e-mail: lhuasvs@yahoo.com.cn
School of Automotive Engineering,
Hubei Key Laboratory of Advanced
Technology of Automotive Parts,
Wuhan University of Technology,
Wuhan, 430070, China

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received April 29, 2011; final manuscript received September 7, 2012; published online December 20, 2012. Assoc. Editor: Robert L. Jackson.

J. Tribol 135(1), 011101 (Dec 20, 2012) (15 pages) Paper No: TRIB-11-1077; doi: 10.1115/1.4007606 History: Received April 29, 2011; Revised September 07, 2012

Cold rotary forging is an advanced but complicated metal forming technology with continuous local plastic deformation. Investigating the wear is significant for effectively predicting the life of the dies and improving the workpiece surface quality. This paper is aimed to use the FE method to predict the wear response over the surfaces of the dies and the workpiece in cold rotary forging. For this purpose, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of 20CrMnTi alloy is developed using the FE software ABAQUS/Explicit and its validity is verified theoretically and analytically. Based on this valid 3D FE model, a systematic study has first been conducted, modeling and explaining the contact pressure and slip distance response. Then, the wear response that occurs at the surfaces of the dies and the workpiece is achieved. Finally, the effect of the process parameters, rotational speed n of the upper die, feed rate v of the lower die, outer/inner diameter of the ring workpiece, on the wear response is revealed. The results of this research help us better understand the complicated wear mechanisms in cold rotary forging. Moreover, the modeling methods proposed in this paper have the general significance to study the wear problems in other complicated metal forming processes.

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References

Figures

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Fig. 1

Schematic illustration of cold rotary forging

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Fig. 2

3D FE model of cold rotary forging under the ABAQUS FE software environment

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Fig. 3

True stress-strain curve of 20CrMnTi alloy

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Fig. 4

Deformed rings under (a) dry and (b) lubricated (MoS2) conditions

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Fig. 5

Friction calibration curves of 20CrMnTi alloy at room temperature under the dry and lubricated conditions

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Fig. 6

Effect of the second contact correction

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Fig. 7

Radial displacement and radial slip distance distribution along the radial direction on the lower surface of the ring workpiece

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Fig. 8

Internal and kinetic energy history curves of the deforming workpiece in the FE process

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Fig. 9

Contact pressure distribution between the dies and workpiece in cold rotary forging

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Fig. 12

Contact pressure variation of the selected nodes in the ring workpiece

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Fig. 13

Contact area variation in cold rotary forging

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Fig. 14

Axial forging force evolution history

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Fig. 15

Slip distance distribution between the upper die and workpiece in cold rotary forging

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Fig. 16

Slip distance distribution between the lower die and workpiece in cold rotary forging

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Fig. 17

Slip distance variation with time

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Fig. 18

Wear distribution over the surfaces of the deformed ring workpiece

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Fig. 19

Effect of the revolution speed n of the upper die on the maximum wear rate

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Fig. 20

Effect of the feed rate v of the lower die on the maximum wear rate

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Fig. 21

Effect of the outer diameter of the ring workpiece on the maximum wear rate

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Fig. 22

Effect of the inner diameter of the ring workpiece on the maximum wear rate

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