WHAT IS ROLLING SIMULATION WITH CAE? – BENEFITS & CASE STUDIES

By utilizing CAE (Computer Aided Engineering) in Rolling, you can predict the deformation of the metal, fracture conditions, heat cracks, and hardness through the process, thereby preventing possible defects. In this article, we will introduce “Rolling”, the benefits of CAE analysis, and case studies.

WHAT IS ROLLING?

Rolling is a method of forming metals into the desired shapes by gradually and repeatedly applying local plastic deformation through the rotation of materials or tools such as sheet metals, pipes, and bars.

The advantages of Rolling are that it can form metals with simple tools, and smaller equipment than pressing needs and that it can form an undercut shape which pressing cannot.

The disadvantage of Rolling is that needs a long time to form the metals, which means it has a low productivity.

These are common Roll forming methods:

• Cross Rolling
• Ring Rolling
• Shape Rolling
• Orbital Forging
• Roll Forging
• Screw Threading
• Spinning
• Back Rolling

BENEFITS OF CAE ANALYSIS FOR ROLLING

CAE analysis for Rolling enables you to predict the deformation of the metal, fracture conditions, heat cracks, and hardness through the process. This allows you to process in appropriate heating conditions and cooling conditions, prevent possible defects that may occur in other processes, and reduce production costs.

CASE STUDIES OF ROLLING SIMULATIONS WITH A CAE SOLUTION

Now, we will introduce you examples of simulations using the CAE software DEFORM.

CASE STUDIES (Click on the image to visit the 3D animation page)

Here are case studies of rolling, ring rolling, spinning, and cross-rolling simulations with DEFORM.

The differences in forming conditions such as rolling velocity and temperature make variations in creating shapes.

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  Orbital Forging The case study of orbital forging simulation. DEFORM supports simulations of complicated die motions including parallel shifts and multi-axial rotation.

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  Roll Forging The case study of roll forging. DEFORM supports simulations of roll forming.

   

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  Shape Rolling The case study of rolling process simulation. DEFORM evaluates temperature change and strain during the process.

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  Back Rolling The simulation of the rolling process of different materials. DEFORM supports simulations using several deformable objects.

   

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  Cross Rolling This is the simulation of cross-rolling. You can see contact conditions and strain distribution during the forming process.

   

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  Screw Threading The case study of screw threading simulation. You can see the strain distribution on the bottom right of the screen.

   

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  Ring Rolling You can see the red line which refers to plastic strain. DEFORM uses the ALE method to make simulation time shorter.

   

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  Ring Rolling You can see how the metals are filled in the die when the ring is rolled into the final shape.

   

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  Ring Rolling DEFORM has a dedicated solver and pre-processor for ring rolling, enabling short-time simulations.

   

CONCLUSION

Thank you for reading!
By utilizing CAE, defects can be prevented in advance, and costs and lead times can be reduced.
In addition to the examples introduced here, the CAE software DEFORM has a wide range of functions to support designers, including other processes, data analysis, the design of an experiment module, and an optimization module.
Please feel free to contact us if you have any questions or concerns about product design and manufacturing.