Advances in Compact Cast-Rolling Forming of Ring-shape Parts
QIN Fangcheng1, QI Huiping2, LI Yongtang2, WU Yonghong2, QI Haiquan1, LIU Chongyu1
1 College of Materials Science and Engineering, Guilin University of Technology, Guilin 541004, China 2 Shanxi Key Laboratory of Metallic Materials Forming Theory and Technology, Taiyuan University of Science and Technology, Taiyuan 030024, China
Abstract: Ring-shape parts such as bearing and flange as the key connect piece, driving medium, rotating member and supporting structure are widely used in major equipment industrial including aerospace, wind power, high-speed rail, ship and high-end numerically-controlled machine. The production in rings is an energy-extensive consumption process. The current technique for ring production mainly includes two kinds: ⅰ) thick plate rolling, bending and welding. The significant stress concentration is presented in the welding areas, which leads to the weak properties in the poor service conditions with high-pressure and corrosion.ⅱ) smelting, ingot pouring, heating, casting, heating, cogging, cutting, rod heating, forging, punching, heating and hot ring rolling. The process is lengthly and the cost of equipments in cogging, forging and punching is huge. The serious energy-consumption and materials wasting in the current process go against environmentally friendly production because of repeatedly heating. The coupling behavior of heat transfer-deformation-microstructure in hot ring rolling results in a complex development of multi-pass, continuous locality loading and unloading, uneven deformation and microstructural evolution with the function of multi-fields and factors. And the geometrical dimensions, microstructure and mechanical properties of the ring blank are significantly affected. As the application of rings develops to large-scale, light-weight, heavy-load and long-life, the demand for manufacturing in high-performance, precision and low cost are proposed. In recent years, the compact cast-rolling compound technique is studied in detail and useful results are obtained. In this process, the ring blank produced by sand casting or centrifugal casting is directly hot rolled. The cogging, forging and punching are leaved and only one heating is needed. Moreover, some advantages of short technological process and materials (above 30%) and energy-conservation (above 60%) are presented. Therefore, the compact process is the inevitable requirement of high-efficiency, high-performance and green manufacturing in the wind power flanges, the petrochemical pressure vessel and numerically-controlled machine base bearing. However, in the hot ring rolling, not only the geometrical dimension of the casting ring blank need to be obtained, but its microstructure and mechanical properties need to be improved and enhanced. A lot of technical challenges occur in the microstructure evolution and performance control of hot ring rolling. Analysis of single-and double-pass compression behavior of casting ring blank, the microstructure evolution rule and its modeling are conducted by researchers. The material constants in the constitutive models considering strain-compensation are established. Furthermore, the simulation of hot rolling with multi-fields coupling of heat transfer-deformation-microstructure, and cross-level coupling of grain topological and mesoscopic-microscopic cellular automaton (CA) are stu-died respectively in detail. The CA models considering grain space overlap is constructed. According to industrial tests, the textural development is introduced to study the control rule of microstructure and mechanical properties in hot rolling of casting ring blank. The grain refinement limitation in different areas of the hot rolled ring is obtained. The results contribute to the achievement of compact cast-rolling compound forming of rings. The research progress on the hot rolling of as-forged ring blank and casting ring blank are summarized. The theories and methods on the integrated control of microstructure and mechanical properties of casting ring blank during the hot rolling are discussed. The crack initiation criterion and processing parameter control on the solidification of casting ring blank are established. The research trends on the hot rolling of the casting ring blank are proposed. The contents and key points in the hot rolling of duplex-metallic casting ring blank are elaborated. This study will promote the development of theory and technique on the integrated control of forming and modification in the compact cast-rolling compound manufacturing of ring parts.
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2020, Vol. 34 
