Three-dimensional FE analysis of ring rolling by employing thermal spokes method

Abstract

This paper investigates the performance of the “Thermal Spokes Method” in modeling the effect of the guide rolls on the ring rolling process. If the guide rolls are not included FE, simulation encounters problems such as tilting of the ring and process instability. Thermal spokes are introduced to withstand any unwanted moment of the resultant rolling forces at the roll gap and to maintain the ring in a centralized location in the mill. By employing the thermal spokes method, much closer predictions for the lateral spread and flow patterns are calculated. This method is able to predict the tilting of the ring with respect to the stiffness of the elements of the adjustment mechanism. It is also possible by this method to predict the point at which the ring changes its support from one guide roll to another one and to study the deformation mechanism outside the roll gap. To verify the validity of the proposed method, the predicted results from this method are compared with some available references. Since the proposed method considers the effect of the guide rolls and consequently offers much closer predictions, it is a very suitable method for ring rolling simulations.