Composite ring rolling - method for manufacturing seamless composite rings on a radial axial ring rolling mill
Final Report Abstract
The overall aim of this project was to enable the production of composite rings by ring rolling. For this purpose, the most important relationships between the process variables and the composite properties were identified and described by models. From this, suitable rolling strategies were derived and permissible process windows were identified. First, an existing finite element (FE) ring rolling model in Abaqus was extended by a contact formulation that considers a developing and loosening bonding between the individual rings during the process. Basic tests to characterize the bonding behaviour then made it possible to simulate the specific bonding behaviour of the investigated material combinations. It was possible to determine process parameters that have a positive influence on the bonding behavior. For this purpose, the influence of the mandrel diameter, the ring growth rate or the length of individual rolling phases was simulated. It was also investigated how the costs for the production of preforms can be reduced despite the different coefficients of thermal expansion of the two materials. With regard to sustainability, simulation studies were carried out on different wall thickness ratios. This made it possible, for example, to produce a lighter composite ring adapted to the application. The validation tests were carried out successfully. The influence of heat treatment was evaluated using tensile tests, ESMA linescans and element mappings. Finally, the knowledge gained was used to investigate a combination of materials with very different flow stresses in FE simulations for the application in detail and to roll a composite ring. For this purpose, a combination of 1.4401 and 1.3505 (corrosion-resistant steel/rolling bearing steel with high strength) was investigated.
Publications
-
Investigation of a composite ring rolling process considering bonding behaviour in FEM and experiment. Procedia Engineering, 207(2017), 1236-1241.
Guenther, Stefan; Seitz, Joachim; Schwich, Gideon & Hirt, Gerhard
-
Verbundringwalzen: Simulation und Experiment zur Herstellung nahtloser Verbundringe. 33. Aachener Stahlkolloquium
Günther, S. & Hirt, G.
-
Werkstoffverbunde ermöglichen anforderungsgerechte Ringe Accessed 31 January 2019
Günther, S. & Hirt, G.
-
Investigation of bond formation behaviour in composite ring rolling. Journal of Materials Processing Technology, 275, 116364.
Guenther, Stefan; Schwich, Gideon & Hirt, Gerhard
-
Auslegung und Herstellung von Verbundringen. 36. ASK Umformtechnik, 235–24
Stergianou, S., Kluge, L., Bailly, D. & Hirt, G.
-
Examination of a Composite Ring Rolling Process with Different Wall Thicknesses to Produce a Ring of 1.7225 and 1.4462 in FEM and Experiment. Lecture Notes in Mechanical Engineering, 266-274. Springer Nature Switzerland.
Kluge, Laurenz; Stergianou, Stefan; Bailly, David & Hirt, Gerhard
-
Extension of a Contact Subroutine for Composite Ring Rolling to Include Temperature Dependency. Journal of Manufacturing and Materials Processing, 8(4), 178.
Kluge, Laurenz; Stergianou, Stefan; Gouverneur, Moritz & Bailly, David
