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Vyacheslav Aleksandrovich Golenkov Sergey Yuryevich Radchenko Daniil Olegovich Dorokhov Theory and Technology of Roll Stamping Theory and Technology of Roll Stamping · Vyacheslav Aleksandrovich Golenkov · Sergey Yuryevich Radchenko Daniil Olegovich Dorokhov Theory and Technology of Roll Stamping VyacheslavAleksandrovichGolenkov SergeyYuryevichRadchenko OrelStateUniversitynamedafterI.S. OrelStateUniversitynamedafterI.S. Turgenev Turgenev Orel,TheOryolArea,Russia Orel,TheOryolArea,Russia DaniilOlegovichDorokhov OrelStateUniversitynamedafterI.S. Turgenev Orel,TheOryolArea,Russia ISBN978-3-030-91816-3 ISBN978-3-030-91817-0 (eBook) https://doi.org/10.1007/978-3-030-91817-0 TranslationfromtheRussianlanguageedition:Teori(cid:2)itehnologi(cid:2)valkovo(cid:3)xtampovki© Oru(cid:4)ieitehnologii2019.PublishedbyOru(cid:4)ieitehnologii.AllRightsReserved. ©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature SwitzerlandAG2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsofreprinting,reuseofillustrations, recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionor informationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Introduction Production of competitive equipment for various purposes requires parts with highmechanicalandphysicalproperties,technologicallysimpleinproductionand economicallyfeasible. Fundamentally,newmetalformingprocessesincludeatechnologywithcomplex local loading of the workpiece plastic deformation zone, which simultaneously combinesbulkstampingandlocaldeformationofthedeformationzonebyspinning rollersordrivenrolls,called“rollstamping.” Themainobjectiveofdevelopinganewmethodandcorrespondingtechnology istoprovidecontrolovertheplasticdeformationprocessandobtainproductswith predeterminedtechnologicalandphysicalproperties.Rollstampingallowstosignifi- cantlyreducethedeformationforce,increasethetoolservicelife,increasesthemetal utilizationrate,reduceorcompletelyeliminatetheneedforsubsequentmachining, anddecreasemetalandenergyconsumptionofequipment. Oneoftheimportantadvantagesofthenewproductionprocessisthecontrolled gradient hardening of the subsurface layers of the product due to periodic local loadingofthedeformationzonewiththesimultaneousapplicationofaglobalmono- tonicload.Thisallowstoformsubmicro-andnanostructuresgradientstartingfrom theoutersurface,whilethevaluesanddistributionofmechanicalpropertiesoverthe volumeoftheproductcanbeplannedinadvance. The existing techniques for calculating local deformation processes, as well as techniques for calculating traditional bulk stamping methods with a fixed region of deforming force application (pressing, extrusion, upsetting, etc.), do not allow calculatingtheprocessesofrollstampingwithasufficientaccuracy.Thismonograph discussestherollstampingtheorybasics,researchofproductionprocesses,aswell asmethodsfortheirdesign. The following researchers from the Oryol State University named after I. S. Turgenev took part in the preparation of the materials for this publication: P. G. Morev,K.I.Kapyrin,G.P.Korotky,T.V.Fedorov,I.M.Gryadunov. v Contents 1 AnalysisofMethods fortheProduction ofAxisymmetric PartswithGivenSpecifications ................................. 1 1.1 Workpiece Forming Methods and Their Effects ontheMechanicalandPhysicalPropertiesofMetals .......... 1 1.2 ClassificationofRollStampingProcesses .................... 9 1.3 HardeningbyMetalFormingMethods ...................... 12 References .................................................... 22 2 DevelopmentoftheCalculationProcedureforProduction ProcessesofMetalForming .................................... 29 2.1 TraditionalMethodsofMetalFormingProcessCalculation ..... 29 2.2 MathematicalProblemDefinitionforMetalForming .......... 31 2.3 Solving Problems of Elastoplastic Deformation bytheFiniteElementMethod .............................. 33 2.3.1 CalculationofTemperatureFields ................... 33 2.3.2 Calculation of Displacements, Deformations andStresses ...................................... 36 2.4 AccuracyEstimationAlgorithms ........................... 37 2.4.1 ResultsAccuracyEstimation ....................... 37 2.4.2 PosteriorEstimatesBasedontheDualityMethod ..... 37 2.4.3 PosteriorEstimatesBasedonCalculationsUsing GridsofDifferentDensities ........................ 42 2.5 DefiningaFiniteElementGrid ............................. 46 2.6 MainAspectsoftheNumericalSolutionofMFProblems ...... 48 2.7 Analysis of Elastoplastic Models Using Dedicated SoftwarePackages ....................................... 54 References .................................................... 54 3 RollStampingofLongBarStock ............................... 57 3.1 AnalysisoftheStress–StrainStateDuringRollStamping ofaStrand-ShapedWorkpiece ............................. 57 3.2 ExperimentalStudiesofRollStampingofLongBarStock ..... 63 vii viii Contents 3.3 LongBarStockRollStampingProcessRefinement ........... 77 References .................................................... 82 4 RollStampingofPieceBlanks .................................. 85 4.1 MetalFlowSpecificsDuringRollStamping .................. 85 4.2 NeutralCross-sectionalAngleandRollStampingProcess Kinematics .............................................. 88 4.3 ConditionsandSpecificsofWorkpieceAxialTightening DuringRollStamping ..................................... 91 References .................................................... 94 5 ForceParametersofRollStamping ............................. 95 5.1 RollStampingStages,AnalysisofChangesinWorking load, and Factors Affecting the Force Parameters oftheDeformationProcess ................................ 95 5.2 Influence of the Relative Deformation Rate ontheWorkpieceRotationCondition ....................... 100 References .................................................... 102 6 MathematicalModelingofRollStamping ....................... 103 6.1 MainObjectivesandSolutionMethods ...................... 103 6.2 TheProcedureforCalculatingToolLoadsDuringRoll Stamping ............................................... 104 6.3 CalculationofRollStampingProcessParametersDuring thePiercingStage ........................................ 104 6.4 CalculationofRollStampingProcessParametersatRoll BurnishingStage ......................................... 115 6.5 StressandDeformationDistributionintheWorkpiece CrossSectionattheRollBurnishingStage ................... 128 6.6 CalculationoftheRollerForceandContactStress,Punch Force,RequiredandCreatedMoments ...................... 130 6.7 MethodologyforCalculatingtheMaximumPermissible RelativeWorkpieceDeformationRate ....................... 140 6.8 DistributionofNormalStressesontheToolDuringRoll Stamping ............................................... 142 References .................................................... 147 7 MainProductionProcessesofRollStamping .................... 149 Reference ..................................................... 157 8 LocalStrainHardening ........................................ 159 8.1 ProblemDefinition ....................................... 159 8.2 CalculationofKinematicandForceParametersofRoll Burnishing .............................................. 160 8.3 MathematicalModelingofRollBurnishing .................. 168 8.4 ExperimentalStudiesofRollBurnishing .................... 173 References .................................................... 175 Contents ix 9 HardeningbyComplexLocalDeformation ...................... 177 9.1 RollBurnishingwithBrakingTorque ....................... 177 9.1.1 The Effect of the Braking Force Applied totheRollerontheDeformationRate ............... 178 9.1.2 Multi-cycleRollBurnishing ........................ 183 9.2 RollBurnishingwithFormingandSmoothingTools ........... 192 9.3 Analysis of the Results of Study of the Forming Tool ShapeandGeometryforHardeningbyComplexLocal LoadingoftheDeformationZone .......................... 201 9.4 MathematicalModelingofComplexLocalDeformation ....... 204 9.5 JustificationofOdqvistParameterastheGenericCriterion for Comparing Physical and Mathematical Modeling Results ................................................. 214 9.6 Influence of the Forming Tool Geometry and Its Indentation Depth on the Stress–Strain State oftheWorkpieceinaSingleActofDeformation .............. 220 9.7 InfluenceofAxialCompressionontheStress–StrainState oftheWorkpieceDuringHardeningbyComplexLocal LoadingoftheDeformationZone .......................... 233 9.8 Study of the Influence of Process Conditions ontheProcessesofHardeningbyComplexLocalLoading oftheDeformationZone .................................. 241 References .................................................... 254 10 ComplexLocalDeformationProcessesandMethodsofTheir Design ....................................................... 259 10.1 ClassificationofComplexLocalDeformationProcesses ....... 259 10.2 Workflow Processes of Complex Local Deformation byRollBurnishing ....................................... 262 10.3 Methodology for Designing MF Methods Based onComplexLocalLoadingoftheDeformationZone .......... 270 10.3.1 Determining Parameters of Roll Burnishing withBrakingTorque .............................. 270 10.4 MethodologyforDesigningRollBurnishingProcesses withFormingandSmoothingToolsUsingtheOdqvist Parameter ............................................... 275 10.4.1 Problem Definition for Design of Metal FormingProcesseswithComplexLocalLoading oftheDeformationZone,AllowingFormation of Gradient-Hardened Structures in Metals andAlloysinaControlledManner .................. 275 x Contents 10.4.2 RecommendationsfortheSelectionofProcess Parameters in the Design of Metal Forming Methods with Complex Local Loading of the Deformation Zone, Allowing Forming Gradient-Hardened Structures in Metals andAlloysinaControlledManner .................. 278 10.5 NewProcessesofHardeningbyComplexLocalLoading oftheDeformationZone .................................. 297 10.5.1 TheProcessofHardeningbyComplexLoading of the Deformation Zone to Obtain Various Mechanical Properties Along the Workpiece Length .......................................... 297 10.5.2 TheProcessofHardeningbyComplexLoading of the Deformation Zone for Forming Using VariousToolsinaSingleProcessingCycle ........... 298 References .................................................... 299 Chapter 1 Analysis of Methods for the Production of Axisymmetric Parts with Given Specifications 1.1 WorkpieceFormingMethodsandTheirEffects ontheMechanicalandPhysicalPropertiesofMetals Axisymmetricpartshavingasteppedouterandinnersurface,longbody,externalor internal thread are widely used due to the most efficient distribution of inner load stressesandtheminimumamountofmaterialsneededfortheirproduction. Productionversionselectionisbasedonthepartproductionaccuracy,production program, design complexity, workpiece and part geometric dimensions, material composition,capabilitiesoftheavailableequipment,aswellasdegreesofscientific validity,development,andexperimentaltestingoftheselectedproductionprocess. Technology selection is mostly based on the final product requirements and its operationspecifics. Axisymmetricpartproductiontechnologyincludescuttingandformingprocesses. Forpartswithhigh-qualityrequirements,cuttinghasthefollowingmaindisadvan- tages:lowmetalutilizationrate(0.2…0.6),lowperformance,aswellastheinability toimprovemechanicalandphysicalpropertiesofparts. While metal forming processes (MF) benefit from work hardening, absence of cuts,macrostructureimprovement,aswellasmetalutilizationrateincreaseupto0.8 andhigher.ThefollowingmainMFprocessesareutilized[1–3]: (cid:129) forging,stampingwithdrophammersandhydraulicpresses; (cid:129) hot stamping with hot-stamping crank presses (HSCP) and horizontal forging machines(HFM); (cid:129) bulkcoldstamping; (cid:129) cross-wedgeandcross-helicalrolling. Forging [4, 5] produces high-quality large workpieces for further processing. Forging is one of the most efficient ways to obtain high-quality workpieces in a dedicatedproductionandtheonlypossiblewaytoobtainlargeworkpieces. ©TheAuthor(s),underexclusivelicensetoSpringerNatureSwitzerlandAG2022 1 V.A.Golenkovetal.,TheoryandTechnologyofRollStamping, https://doi.org/10.1007/978-3-030-91817-0_1