Influence of ring growth rate on damage development in hot ring rolling

C. Wang, H. J.M. Geijselaers, E. Omerspahic, V. Recina, A. H. van den Boogaard

    Research output: Contribution to journalArticleAcademicpeer-review

    13 Citations (Scopus)

    Abstract

    As an incremental forming process of bulk metal, ring rolling provides a cost effective process route to manufacture seamless rings. In the production of hot rolled rings, defects such as porosity can sometimes be found in high alloyed steel, manufactured from ingots having macro-segregation. For the reduction of the waste of material and improvement of product quality, a better understanding of the relations between parameters in the hot ring rolling process and the occurrence of porosity is needed. In this study round bars were used to manufacture rings on an industrial ring rolling mill. Different ring growth rates were applied to investigate the influence on the occurrence of porosity in the final rings. The hot rolled rings were inspected by ultrasonic testing, of which the results were also validated by metallographic investigation. In addition to the experimental investigations, coupled thermo-mechanical multi-stage finite element (FE) analysis was performed with integrated adaptive motion control of the rolls. A damage indicator was implemented in a user-defined elasto-viscoplastic material model. The deformations, stresses as well as temperature history from preform forging were included as initial conditions for the rolling stage. Damage indication from the numerical model matches the experimental result in the considered process conditions. In spite of the suggestion of a more careful process when a low ring growth rate is used in hot ring rolling, experimental and numerical studies demonstrate that with a low ring growth rate there is an increased susceptibility to damage as compared to application of a high ring growth rate.
    Original languageEnglish
    Pages (from-to)268-280
    JournalJournal of materials processing technology
    Volume227
    DOIs
    Publication statusPublished - 20 Aug 2015

    Fingerprint

    Porosity
    Ultrasonic testing
    Steel
    Rolling mills
    Motion control
    Ingots
    Forging
    Macros
    Numerical models
    Metals
    Finite element method
    Defects
    Costs
    Temperature

    Keywords

    • IR-97051
    • METIS-311514

    Cite this

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    title = "Influence of ring growth rate on damage development in hot ring rolling",
    abstract = "As an incremental forming process of bulk metal, ring rolling provides a cost effective process route to manufacture seamless rings. In the production of hot rolled rings, defects such as porosity can sometimes be found in high alloyed steel, manufactured from ingots having macro-segregation. For the reduction of the waste of material and improvement of product quality, a better understanding of the relations between parameters in the hot ring rolling process and the occurrence of porosity is needed. In this study round bars were used to manufacture rings on an industrial ring rolling mill. Different ring growth rates were applied to investigate the influence on the occurrence of porosity in the final rings. The hot rolled rings were inspected by ultrasonic testing, of which the results were also validated by metallographic investigation. In addition to the experimental investigations, coupled thermo-mechanical multi-stage finite element (FE) analysis was performed with integrated adaptive motion control of the rolls. A damage indicator was implemented in a user-defined elasto-viscoplastic material model. The deformations, stresses as well as temperature history from preform forging were included as initial conditions for the rolling stage. Damage indication from the numerical model matches the experimental result in the considered process conditions. In spite of the suggestion of a more careful process when a low ring growth rate is used in hot ring rolling, experimental and numerical studies demonstrate that with a low ring growth rate there is an increased susceptibility to damage as compared to application of a high ring growth rate.",
    keywords = "IR-97051, METIS-311514",
    author = "C. Wang and Geijselaers, {H. J.M.} and E. Omerspahic and V. Recina and {van den Boogaard}, {A. H.}",
    year = "2015",
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    Influence of ring growth rate on damage development in hot ring rolling. / Wang, C.; Geijselaers, H. J.M.; Omerspahic, E.; Recina, V.; van den Boogaard, A. H.

    In: Journal of materials processing technology, Vol. 227, 20.08.2015, p. 268-280.

    Research output: Contribution to journalArticleAcademicpeer-review

    TY - JOUR

    T1 - Influence of ring growth rate on damage development in hot ring rolling

    AU - Wang, C.

    AU - Geijselaers, H. J.M.

    AU - Omerspahic, E.

    AU - Recina, V.

    AU - van den Boogaard, A. H.

    PY - 2015/8/20

    Y1 - 2015/8/20

    N2 - As an incremental forming process of bulk metal, ring rolling provides a cost effective process route to manufacture seamless rings. In the production of hot rolled rings, defects such as porosity can sometimes be found in high alloyed steel, manufactured from ingots having macro-segregation. For the reduction of the waste of material and improvement of product quality, a better understanding of the relations between parameters in the hot ring rolling process and the occurrence of porosity is needed. In this study round bars were used to manufacture rings on an industrial ring rolling mill. Different ring growth rates were applied to investigate the influence on the occurrence of porosity in the final rings. The hot rolled rings were inspected by ultrasonic testing, of which the results were also validated by metallographic investigation. In addition to the experimental investigations, coupled thermo-mechanical multi-stage finite element (FE) analysis was performed with integrated adaptive motion control of the rolls. A damage indicator was implemented in a user-defined elasto-viscoplastic material model. The deformations, stresses as well as temperature history from preform forging were included as initial conditions for the rolling stage. Damage indication from the numerical model matches the experimental result in the considered process conditions. In spite of the suggestion of a more careful process when a low ring growth rate is used in hot ring rolling, experimental and numerical studies demonstrate that with a low ring growth rate there is an increased susceptibility to damage as compared to application of a high ring growth rate.

    AB - As an incremental forming process of bulk metal, ring rolling provides a cost effective process route to manufacture seamless rings. In the production of hot rolled rings, defects such as porosity can sometimes be found in high alloyed steel, manufactured from ingots having macro-segregation. For the reduction of the waste of material and improvement of product quality, a better understanding of the relations between parameters in the hot ring rolling process and the occurrence of porosity is needed. In this study round bars were used to manufacture rings on an industrial ring rolling mill. Different ring growth rates were applied to investigate the influence on the occurrence of porosity in the final rings. The hot rolled rings were inspected by ultrasonic testing, of which the results were also validated by metallographic investigation. In addition to the experimental investigations, coupled thermo-mechanical multi-stage finite element (FE) analysis was performed with integrated adaptive motion control of the rolls. A damage indicator was implemented in a user-defined elasto-viscoplastic material model. The deformations, stresses as well as temperature history from preform forging were included as initial conditions for the rolling stage. Damage indication from the numerical model matches the experimental result in the considered process conditions. In spite of the suggestion of a more careful process when a low ring growth rate is used in hot ring rolling, experimental and numerical studies demonstrate that with a low ring growth rate there is an increased susceptibility to damage as compared to application of a high ring growth rate.

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    KW - METIS-311514

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    DO - 10.1016/j.jmatprotec.2015.08.017

    M3 - Article

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    JO - Journal of materials processing technology

    JF - Journal of materials processing technology

    SN - 0924-0136

    ER -