Numerical simulation of a cross-wedge rolling process in a mill with horizontally stacked rolls

ABSTRACT: This paper presents simulations of the cross wedge rolling (CWR) process of a railway axle. It is assumed that the rolls are arranged horizontally, which should facilitate both the loading of the charge and the unloading of the rolled product. Simulations were performed in the Forge® programme, based on the finite element method (FEM). It was found that the adopted rolling scheme and design of wedge tools ensures the achievement of a correctly formed railway axle, free of internal (cracks) and external defects (overlapping, bending). The force parameters determined in the simulations can be used in the design works of the rolling mill guaranteeing the railway axle forming process.

KEYWORDS: cross-wedge rolling, railway axle, FEM

STRESZCZENIE: Przedstawiono symulacje procesu walcowania poprzeczno-klinowego (WPK) osi kolejowej. Przyjęto, że walce ułożone są poziomo, co powinno ułatwić zarówno załadowanie wsadu, jak i wyładowanie odwalcowanego wyrobu. Symulacje wykonano w programie Forge®, bazującym na metodzie elementów skończonych (MES). Stwierdzono, że przyjęty schemat walcowania oraz konstrukcja narzędzi klinowych zapewniają uzyskanie prawidłowo ukształtowanej osi kolejowej, wolnej od wad wewnętrznych (pęknięć) i zewnętrznych (zawalcowań, wygięć). Określone w symulacjach parametry siłowe można wykorzystać w pracach projektowych walcarki zabezpieczającej proces kształtowania osi kolejowych.

SŁOWA KLUCZOWE: walcowanie poprzeczno-klinowe, oś kolejowa, MES

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DOI: https://doi.org/10.17814/mechanik.2022.5-6.7

 

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