بررسي نرخ سايش غلتك‌ها در فرايند شكل‌دهي مجدد غلتكي سرد به‌كمك شبيه‌سازي اجزاي محدود

Analysis of Roll Wear in Reshaping Using Finite Element Simulation

اين مقاله به بررسي اثرات سايش غلتكها و شبيه‌سازي اين پديده در فرايند شكل‌دهي مجدد غلتكي اختصاص دارد. براي شبيه‌سازي پديده سايش و بررسي نرخ سايش غلتكها از نرم‌افزار شبيه‌سازي اجزاي محدود ABAQUS استفاده شده است. قطعه توليدي مورد نظر در شبيه‌سازي فرايند شكل‌دهي مجدد غلتكي سرد داراي پروفيل مربعي است. پس از انجام شبيه‌سازي با توجه به مدل سه‌بعدي ايجاد شده، ناحيه‌هاي مستعد سايش روي غلتك‌ها بررسي مي‌شوند. همچنين اثر تغيير پارامترهاي مهم مانند جنس، ضريب اصطكاك و ضخامت ورق بر روي سايش غلتك‌ها بررسي شده است. در انتها به منظور اعتبارسنجي، نتايج حاصل از شبيه‌سازي با نتايج مطالعات تجربي موجود، مقايسه شده است.

Reshaping process is a widely used method for producing tubes with non-circular cross sections. Owing to the friction between pipe and rolls, initial round pipe moves forward and consequently, it gradually formed into square or rectangular one. In practice, geometric profile of the rolls will be changed after a while. These changes would be detrimental the production of faultless products. Therefore, in this paper the reshaping process is studied considering wear phenomena on the rolls. This study is a co-operation with a related industry at which square tubes are produced using reshaping process. In order to investigate the production line, considering industrial datasheets, the process is modeled by means of a commercial FEM package, ABAQUS\Explicit. The reshaping process is simulated as a 3D model and subsequently the sustainable regions to wear are investigated. The influences of significant parameters such as material and thickness of strip, as well as friction coefficient on the worn area, are studied. At the end, the FEM reults are comprised with the experiments reults and a good consistency between them is seen.