Control of ring rolling with variable thickness and curvature

Matthew Arthington, Jos Havinga, Stephen Duncan*

*Corresponding author for this work

    Research output: Contribution to journalArticleAcademicpeer-review

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    Abstract

    Radial-Axial Ring Rolling (RARR) is an industrial forging process for making strong, seamless metal rings. Conventionally, rings are made circular with constant cross-section. In this work we demonstrate a sensing and control strategy to create rings with variable radial wall thickness and variable curvature using standard RARR hardware. This has a number of potentially useful applications but also provides an understanding of how to control these properties for conventional RARR. The sensing uses a calibrated video camera to take a series of images of the ring top surface. Image processing is employed to measure and track the ring material in-situ. The complete state of the ring is represented by the ring thickness and curvature as a function of its volume fraction, which is computed by combining the measurements from the unoccluded areas with estimates of the ring shape elsewhere. Additionally, we present a marking technique for tracking of material as it rotates through the rolling machine, even after significant deformation of the ring has occurred. We show that rings with a wide range of variation in local thickness and curvature can be formed using conventional RARR hardware and a photogrammetric state measurement technique, combined with open-loop scheduling and feedback control of thickness and curvature. Rings with both variable thickness and non-circular shapes have been produced virtually using numerical simulations and in reality using modelling clay as a material to simulate metals at forging temperatures. We demonstrate that this technique extends the range of shapes achievable with standard RARR hardware.
    Original languageEnglish
    JournalInternational journal of material forming
    DOIs
    Publication statusE-pub ahead of print/First online - 6 Feb 2019

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    Keywords

    • UT-Hybrid-D
    • Process control
    • Digital image correlation
    • Industrial control
    • Ring rolling
    • Variable geometry
    • Process automation

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