Simulation of cross wedge rolling with FORGE®
Cross wedge rolling, like reducer rolling, is a process used to produce preforms, most commonly employed in the automotive industry. This rolling technique combines high productivity, long die life and good material efficiency (no waste produced). Simulation of this preform process allows determining the distribution of state variables (temperature, strain, and stress). Incorporating these values in the simulation of a subsequent forming process increases the accuracy level of the entire process chain simulation.
FORGE® features a precise contact algorithm and a temporal integration scheme for updating the coordinates naturally adapted to rotation which render the simulation of cross wedge rolling highly accurate. Resorting to tricks such as forcing component rotation or blocking its displacement is thus unnecessary. Simulation, in this case, becomes a real predictive tool which can be used to fine-tune the process.
Simulation of cross wedge rolling. Courtesy Lublin University of Technology.
FORGE® allows an accurate prediction of:
- The geometry of the preform at the end of the cross wedge rolling stage,
- Presence of folds/laps or other defects,
- All the state variables, like for example the equivalent strain in order to take it into account in the subsequent operations,
- Torques and loads to apply on the rolls.
- Real kinematic applied on the rolls,
- Volume conservation of the preform during the simulation thanks to an appropriate rotational update scheme,
- Easy prediction of flaws including Mannesmann effect
- Chaining with subsequent forming operations.