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1 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
SIMULATION OF THE RING ROLLING PROCESS TAKING INTO
ACCOUNT AUTOMATIC MOTION CONTROL
-
PREDICTION OF MICROSTRUCTURE
PATRICE LASNE, AMICO SETTEFRATI, MICKAEL BARBELET
2 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF A SHAPED RING
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
3 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF A SHAPED RING
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
4 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
Ring-rolling is a complex incremental process Large number of revolutions
Small area of contact
Number of works have been done to improve simulation of the
Ring-Rolling Process Optimum Meshing
Parallel computing
ALE Formulation
Automatic Centering
Contact smoothing method
…
5 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF A SHAPED RING
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
6 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RING ROLLING PILOTING
Conical
Rolls
King-Roll
Centering-Rolls Mandrel
7 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RING-ROLLING PILOTING
h Ring height
with FORGE : use of ‘automatic centering’ option
to avoid centering rolls piloting
Ring thickness
s
D Ring Outer Diameter
8 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
SIMPLE EXAMPLE OF PILOTING
Industrial ring rolling mill piloting data :
Mandrel velocity : Vmandrel = f(Dring)
Ring height : Hring = f(Dring)
Rotation speed for the king roll : constant
Rotation speed for the mandrel & axial conical rolls : automatic rotation
9 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
SIMPLE EXAMPLE OF PILOTING
10 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF RING-SHAPED PROFILE
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
11 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING
Material description : Inconel 718
Elasto-plastic behaviour :
JmatPro (Sente-Software) data :
thpe
eeee Itracedt
d
2 ,...,,00 Tpp
12 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING
Initial bulk forging sequence:
Upsetting Preforming Piercing
13 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING Conical
Roll
King-Roll
Mandrel
Laser measurement
14 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING
Laser measurement h Ring height
D Ring Outer Diameter
Ring thickness
s
15 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING Industrial ring rolling mill piloting data :
Ring Growth Speed :
Ring Height : Hring = f(Tring)
Rotation speed for the king roll : constant
Rotation speed for the mandrel & axial conical roll : automatic rotation
)( ring
ringDf
dt
dD
16 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
INDUSTRIAL EXAMPLE – SHAPED RING
17 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF A SHAPED RING
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
18 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING
19 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING
20 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING
Recrystallization model
Dynamic Recrystallysation
Post-Dynamic Recrystallization :
Grain Growth :
drxn
c
cdrxX
5.0
).2ln(exp1),,(
.
02 Tdfdwith
Xdd
d
adrx
drxddrx
pdrx
pdrx
n
pdrxt
tX
5,0
).2ln(exp1),,,(
.
04 Tdfdwith
Xdd
p
apdrx
pdrxppdrx
tRT
QGdd
Ggr
g
GgGg
gg .exp2
1
0
1
21 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING 3 Population of grains
Dynamic recrystallized
Meta-dynamic recrystallized
Non recrystallized
22 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING Grain size evolution
Dynamic recrystallized
Meta-dynamic recrystallized
Non recrystallized
23 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
RECRYSTALLIZATION DURING RING-ROLLING Grain size evolution
Dynamic recrystallized
Meta-dynamic recrystallized
Non recrystallized
24 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
CONTEXT
INTRODUCTION TO RING ROLLING PILOTING
INDUSTRIAL EXAMPLE OF A SHAPED RING
RECRYSTALLIZATION DURING RING ROLLING
PERSPECTIVES & CONCLUSIONS
OVERVIEW
25 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
A more complete piloting approach to avoid current limitations
We do not take into account ring mill limitations (force, torque)
The automatic centering option may not be “100% perfect”
It is very difficult to have feedback about the piloting of industrial ring mills
Black box :
A lot of input parameters can be used as input :
Ring measurements (D, s, h, …)
Velocities / Rotation speeds
Forces / Torques
…
Output :
Imposed velocities / Imposed rotation speeds
Imposed forces / Imposed torques
…
PERSPECTIVES & CONCLUSIONS
26 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
Solutions Increase know-how based on collaborative work with ring rolling mill manufacturers
Open Forge software to allow the definition of complex piloting
(e.g. External module for User Piloting)
PERSPECTIVES & CONCLUSIONS
shD
F
V
,,
,
,
External
User
Piloting
At each
increment
...
,
,
impimp
impimp
F
V
27 Complas XII, International Conference on Computational Plasticity Fundamentals and Applications 3 - 5 September 2013, Barcelona
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FOR YOUR ATTENTION
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