Ring Rolling is a complex manufacturing process that is performed to create large high quality seamless rings for the gas turbine industry. The objective of the simulation in to predict the material flow during the process, the resultant microstructure, and ultimately to optimize the tooling required for forming complex profiles. Ring rolling involves many stages including upsetting, punching, thermal processes (both quenching and annealing) and the rolling. Furthermore, for complex profiles, the rolling involves multiple sets of tools. This paper will consider these different processes and compare the numerical simulation with experimental behavior.
Development of a Simulation Tool for Multi-pass Ring Rolling
The Preform in Motion
Ring Mill #1
Ring Mill #2
and The Final Sizing
Current: 100# Forged 12# Fly
Get the red out...
... and reduce mfg. risk
Target: 65# Forged 12# Fly
Ring Rolling Simulation Overview
Expand PreformTo Fit Over Mandrel
Rolling Simulation
Ring Rolling SimulationMajor Components Mandrel Axial Roller
Ring Main Roller Axial Roller
Aggressive IndentationSmall Roll Draft (Decrease ) To Evaluate
Roller Shapes
Typical IndentationRoll Draft Increased To Typical Values
Typical IndentationClose View of Main Roller and Ring
Five Mandrel and Two Main Profiles
Compute TimeCurrent Simulation = 4CPUdays/revolution
Another Ring Roll Simulation
Roll a 3D Sector
Repeat Options: Loop or Swing
Ring Sector In a Freely Rotating Rigid Cylindrical BoxPiano
Hinge Translates in Cutting Plane as Ring Expands
Top and bottom of box prevent axial growth of more than 22
inches
Roll a 3D 45 Sector
o
Plastic Strain Contours To be Repeated ~50x
Note Increasing Radius
Roll a 3D 45 Sector
o
Plastic Strain Contours On Cutting Plane
Repeat by Oscillating
3D Sector: One CycleTarget = 30 in
Target = 4500 inc
Increase in Ring Radius [in]
Project to Target
Sector Model Achieved TargetRing Diameter [in]
Stage 5
Stage 4
Stage 3
Stage 2
Stage 1
Sector at Intermediate Positions
Sector Run To Completion
Sector Run To Completion
Sector Predicts Under Fill
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Radial Growth of Work PieceRing Growth90Ring Major Inner
Diameterprocess data range
80 70 60 50 40 30 20 10 0 0 1 2 3 Forming Stage 4 5 6
3D Sector to a Generalized Plane Strain Simulation (2D-GPE)
2D-GPE Simulation
2D Rolled Versus Design ShapeRolled Near Net Shape
Machined Shape Preform
Compare 2D-GPE to 3D Sector
2D-GPE
3D Sector Cut Plane
527 0.57
Number of Elements (in plane) Maximum Plastic Strain
100 0.95
Compare 2D-GPE to 3D Sector3D less radial flow due to 2D axial
flow bulging and top and bottom plates 3D more radial flow
2D more axial flow
Compare at the End
2D-GPE
3D Sector Cut Plane
2D Doesnt predict under fill
1035 2.6
Number of Elements (in plane) Maximum Plastic Strain
523 4.3
Compare 3D Full to 3D Sector
Little more radial flow in 3D Full
Same axial flow
Compute Times300 Rev
Estimated ImprovementsPPM 4X
Year
MonthDraft 2X
300 RevChips 2X Template 1.5X
Week 1 Rev
Phase II Complete 1 Rev
Conclusions & Recommendations
Full 3D simulation desirable but takes too much time as a design
tool 3D sector simulation reasonable and predicts experience 2D
simulations not realistic Future includes: Technology transfer from
MSC to Firth Rixson Viking Software improvements for sector and
full 3D simulations - like template remeshing
Template Remeshing
Summary
