Large concavity at the end of the workpiece formed by cross wedge rolling without stub bar results in material loss. The forming process of cross wedge rolling was simulated by finite element method, revealing the reason of concavity at the end by comparing the displacement and strain with and without stub bar. A billet with a tapered end was proposed, and its optimum parameters were obtained to reduce material loss on the concavity by more than 90%. The forming quality was investigated under three typical forming conditions, and it was found that the significant increase of transverse tensile stress, shear stress and shear strain at the end centre of the workpiece formed without stub bar results in the risk of central damage. The results of finite element simulation were verified by rolling experiments, and the prediction of central damage was confirmed by the microstructure of the workpiece. As a result, a billet with an appropriate tapered end not only save materials but also avoid the risk of central damage at the end of the workpiece.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Nov 2, 2017
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