This book gives a complete overview of the roll stamping process of metal forming. This fundamentally new technique features an integrated local loading of the plastic deformation zone of the workpiece, simultaneously combining the die forging operation and local deformation of the deformation zone by rotating rollers or drive rolls. The book presents the basics of the theory behind roll stamping, delivering a complete technical analysis including the key results of mathematical modeling studies and a discussion of methodologies for designing novel roll stamping techniques. The aim of the new metal forming processes proposed in the book is directed toward the production of competitive equipment for fabrication of various mechanical parts having enhanced materials and physical properties in combination with a low cost of production and maintenance. This book is an ideal resource for any student or practicing engineer working with the roll stamping process.
Author(s): Vyacheslav Aleksandrovich Golenkov, Sergey Yuryevich Radchenko, Daniil Olegovich Dorokhov
Publisher: Springer
Year: 2022
Language: English
Pages: 315
City: Cham
Introduction
Contents
1 Analysis of Methods for the Production of Axisymmetric Parts with Given Specifications
1.1 Workpiece Forming Methods and Their Effects on the Mechanical and Physical Properties of Metals
1.2 Classification of Roll Stamping Processes
1.3 Hardening by Metal Forming Methods
References
2 Development of the Calculation Procedure for Production Processes of Metal Forming
2.1 Traditional Methods of Metal Forming Process Calculation
2.2 Mathematical Problem Definition for Metal Forming
2.3 Solving Problems of Elastoplastic Deformation by the Finite Element Method
2.3.1 Calculation of Temperature Fields
2.3.2 Calculation of Displacements, Deformations and Stresses
2.4 Accuracy Estimation Algorithms
2.4.1 Results Accuracy Estimation
2.4.2 Posterior Estimates Based on the Duality Method
2.4.3 Posterior Estimates Based on Calculations Using Grids of Different Densities
2.5 Defining a Finite Element Grid
2.6 Main Aspects of the Numerical Solution of MF Problems
2.7 Analysis of Elastoplastic Models Using Dedicated Software Packages
References
3 Roll Stamping of Long Bar Stock
3.1 Analysis of the Stress–Strain State During Roll Stamping of a Strand-Shaped Workpiece
3.2 Experimental Studies of Roll Stamping of Long Bar Stock
3.3 Long Bar Stock Roll Stamping Process Refinement
References
4 Roll Stamping of Piece Blanks
4.1 Metal Flow Specifics During Roll Stamping
4.2 Neutral Cross-sectional Angle and Roll Stamping Process Kinematics
4.3 Conditions and Specifics of Workpiece Axial Tightening During Roll Stamping
References
5 Force Parameters of Roll Stamping
5.1 Roll Stamping Stages, Analysis of Changes in Working load, and Factors Affecting the Force Parameters of the Deformation Process
5.2 Influence of the Relative Deformation Rate on the Workpiece Rotation Condition
References
6 Mathematical Modeling of Roll Stamping
6.1 Main Objectives and Solution Methods
6.2 The Procedure for Calculating Tool Loads During Roll Stamping
6.3 Calculation of Roll Stamping Process Parameters During the Piercing Stage
6.4 Calculation of Roll Stamping Process Parameters at Roll Burnishing Stage
6.5 Stress and Deformation Distribution in the Workpiece Cross Section at the Roll Burnishing Stage
6.6 Calculation of the Roller Force and Contact Stress, Punch Force, Required and Created Moments
6.7 Methodology for Calculating the Maximum Permissible Relative Workpiece Deformation Rate
6.8 Distribution of Normal Stresses on the Tool During Roll Stamping
References
7 Main Production Processes of Roll Stamping
Reference
8 Local Strain Hardening
8.1 Problem Definition
8.2 Calculation of Kinematic and Force Parameters of Roll Burnishing
8.3 Mathematical Modeling of Roll Burnishing
8.4 Experimental Studies of Roll Burnishing
References
9 Hardening by Complex Local Deformation
9.1 Roll Burnishing with Braking Torque
9.1.1 The Effect of the Braking Force Applied to the Roller on the Deformation Rate
9.1.2 Multi-cycle Roll Burnishing
9.2 Roll Burnishing with Forming and Smoothing Tools
9.3 Analysis of the Results of Study of the Forming Tool Shape and Geometry for Hardening by Complex Local Loading of the Deformation Zone
9.4 Mathematical Modeling of Complex Local Deformation
9.5 Justification of Odqvist Parameter as the Generic Criterion for Comparing Physical and Mathematical Modeling Results
9.6 Influence of the Forming Tool Geometry and Its Indentation Depth on the Stress–Strain State of the Workpiece in a Single Act of Deformation
9.7 Influence of Axial Compression on the Stress–Strain State of the Workpiece During Hardening by Complex Local Loading of the Deformation Zone
9.8 Study of the Influence of Process Conditions on the Processes of Hardening by Complex Local Loading of the Deformation Zone
References
10 Complex Local Deformation Processes and Methods of Their Design
10.1 Classification of Complex Local Deformation Processes
10.2 Workflow Processes of Complex Local Deformation by Roll Burnishing
10.3 Methodology for Designing MF Methods Based on Complex Local Loading of the Deformation Zone
10.3.1 Determining Parameters of Roll Burnishing with Braking Torque
10.4 Methodology for Designing Roll Burnishing Processes with Forming and Smoothing Tools Using the Odqvist Parameter
10.4.1 Problem Definition for Design of Metal Forming Processes with Complex Local Loading of the Deformation Zone, Allowing Formation of Gradient-Hardened Structures in Metals and Alloys in a Controlled Manner
10.4.2 Recommendations for the Selection of Process Parameters in the Design of Metal Forming Methods with Complex Local Loading of the Deformation Zone, Allowing Forming Gradient-Hardened Structures in Metals and Alloys in a Controlled Manner
10.5 New Processes of Hardening by Complex Local Loading of the Deformation Zone
10.5.1 The Process of Hardening by Complex Loading of the Deformation Zone to Obtain Various Mechanical Properties Along the Workpiece Length
10.5.2 The Process of Hardening by Complex Loading of the Deformation Zone for Forming Using Various Tools in a Single Processing Cycle
References
