3D coupled thermo-mechanical FE analysis of roll size effects on the radial–axial ring rolling process

Radial–axial ring rolling is an advanced but complicated incremental metal forming technique with multi-factors coupling interactive effects. During the radial–axial ring rolling process, the deformation and thermal behaviors of the ring mainly occur in the roll passes which are constituted by rolls. So, the rolls sizes have enormous influence on the quality of the rolled ring as well as the stability of the process. In this paper, the ranges of rolls sizes and forming parameters are reasonably determined at first, then a 3D elastic–plastic and coupled thermo-mechanical FE model of radial–axial ring rolling is developed using the dynamic explicit code ABAQUS/Explicit, and its reliability is verified theoretically and experimentally. Based on the valid 3D FE model, the size effects of rolls on the radial–axial ring rolling process are investigated. The research results provide valuable guidelines for the design and optimization of the rolls sizes in the actual radial–axial ring rolling production.

Research highlights
► The ranges of rolls sizes and forming parameters are determined.
► 3D coupled thermo-mechanical FE model of radial-axial ring rolling is developed.
► The reliability of the FE model is verified theoretically and experimentally.
► The size effects of rolls on the quality of the rolled ring are investigated.
► The size effects of rolls on the consumption of the power parameters are analysed.