Incremental ring rolling to create conical profile rings

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1 Available online at ScienceDirect Procedia Engineering 207 (2017) International Conference on the Technology of Plasticity, ICTP 2017, September 2017, Cambridge, United Kingdom Incremental ring rolling to create conical profile rings Christopher J. Cleaver a *, Julian M. Allwood a a Department of Engineering, University of Cambridge, Trumpington Street, Cambridge, CB2 1PZ Abstract A key application for ring rolled products used in turbomachinery and other engineering machines are components which take the form of a hollow truncated cone, or 'conical profile'. These are currently rolled close to net-shape shape using expensive part specific tooling or cut from a simple rectangular cross-section rolled ring. In this paper, efforts to create conical profiles by a novel 'incremental ring rolling' process are described. Three types of conical profile which require challenging redistribution of material throughout the workpiece were targeted: an inner taper, outer taper and a flanged cone. Experiments carried out on lead workpieces suggest that such profiles are attainable by constrained incremental ring rolling and defects such as underfilling (outer taper and flanged cone), dishing (inner taper) and unwanted conicity (inner taper) can be reduced. Ultimately this could be exploited to either save material and machining time or reduce tooling costs The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the scientific committee of the International Conference on the Technology of Plasticity. Keywords: Ring rolling; net-shape forming 1. Introduction Ring rolling is a metal forming process for making seamless semi-finished rings, often used to produce annular components in aerospace, oil and gas, electricity generation industries. In the typical process, shown in Fig. 1a, a preform prepared by upset forging and piercing is acted on by two pairs of rolls that reduce the wall thickness and height respectively in multiple passes as the workpiece rotates, stabilized by a pair of guide rolls. An important * Corresponding author. Tel.: address: cjc82@cam.ac.uk The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the scientific committee of the International Conference on the Technology of Plasticity /j.proeng

2 Christopher J. Cleaver et al. / Procedia Engineering 207 (2017) application of rolled rings is components with a conical profile, in some way resembling a hollow truncated cone. Such components include tapered bearings and turbomachinery casings amongst others as illustrated in Fig. 1b. Currently it is only possible to form such shapes by ring rolling if costly part-specific shaped tooling is used, as schematically shown in Fig. 1c, often also requiring the use of a shaped preform [1]; otherwise the shape is cut away from a rectangular cross-section ring. Ideally it would be possible to create conical ring shapes by ring rolling without part-specific tooling; the focus of this paper. Such a process would minimize the cost of raw material and energy input, downstream machining and potentially enhance the product mechanical properties and microstructure. Fig. 1. (a) Conventional radial-axial ring rolling; (b) schematic of applications of conical rings (c) profile rolling with shaped tooling. 2. Incremental ring rolling: options for creating conical profiled rings A possible solution for creating shaped cross-sections without dedicated tooling is incremental ring rolling (IRR), as originally proposed by Allwood et. al. [2]. In this, an inner or outer radial tool shorter than the full height of the ring can be programmed to move both vertically and horizontally and is able to reduce the thickness of the ring by different amounts along its height, as indicated in Fig. 2a. The first experimental trials with such a process showed mixed results. In Fig. 2b a C shape cross-section was targeted in wax material, but due to non-uniform circumferential material flow the ring appears to bulge [2]. In Fig. 2c an L shape cross-section was targeted in steel, but for similar reasons the ring becomes conical and dishing lifting of the bottom surface - is also present [2]. Seitz has exploited a dishing effect caused by the conical axial rolls to create moderately shaped disk-like rings [4]. Recently the authors introduced the axial and circumferential constraints shown in pink in Fig. 2a [5] to increase control over material flow and demonstrated these by creating an L-shape ring with improved accuracy- see Fig. 2d. Fig. 2. (a) Incremental ring rolling process (IRR) (b) IRR trials in wax (c) IRR trials in steel (d) constrained IRR in lead In this work the intention is to produce conical ring shapes from an initially rectangular cross-section preform. An option for achieving this might be to exploit the conicity defect seen in Fig. 2c, where regions reduced in thickness the most flare outwards circumferentially. However, this is limited to shapes with those characteristics.

3 1250 Christopher J. Cleaver et al. / Procedia Engineering 207 (2017) Instead, three new challenging target shapes are investigated in which the regions with the thinnest wall (which undergo the most radial thinning) have either the same or smaller radius than the rest of the ring as shown in Figure 3. These are labelled inner taper in which the inner surface is inclined at an angle α to the ring axis (Fig. 3a), outer taper with an inclined outer surface (Fig 3b) and finally flanged cone with a thinner walled upper region with both walls inclined to the ring axis and the thicker walled lower flange which protrudes radially Fig. 3c. 3. Methodology Fig. 3. Three conical profile shapes targeted in this paper a. Inner taper, b. Outer taper, c. Flanged cone Attempts were made to make these three conical ring shapes by incremental ring rolling, on the University of Cambridge constrained IRR machine, with tooling and degrees of freedom as shown in Fig. 2a [5]. The workpiece material in all cases is BS EN Lead as a model for the behavior of steel alloys in hot working conditions. Two inner taper rings were made with taper angle, α, of 15 o and 30 o. The set-up is shown in Fig. 4a; the inner mandrel retracts vertically down as the radial roll gap is closed. In early testing the ring was found to climb out of plane. To stop this, two new circumferential constraint rolls were used in positions 3 and 4 (numbered clockwise from the forming roll), with a lip to constrain the ring vertically. Constraint roll 1 was set to apply a radial force to the ring and the remaining rolls were controlled to move symmetrically, so that on average the forces were as reported in Table 1. In all experiments, except stage 2 of the flanged cone, the force was maximized to promote the required axial material redistribution, limited either by the machine force limits or the ability of the ring to rotate. The effect of varying this force is briefly discussed later. The upper and lower axial rolls were fixed vertically. The inner taper toolpaths were determined as follows. The 15 o and 30 o rings were made with the same average wall thickness to make the comparison clearer. The 15 o toolpath is detailed in Fig. 5a which plots the locus of the point A (Fig 4a.). After reducing to 33.4mm, the taper is formed by rotating the ring for 1 revolution, retracting the mandrel, moving it vertically downwards and then re-engaging with a 1% smaller roll-gap for the next revolution. This discrete approach was used to monitor and react to problems such as slipping of the ring relative to the forming roll, but in principal a continuously reducing roll gap could be used. It emerged that despite the axial and circumferential constraints some dishing and conicity errors still occurred. A second finishing pass was used to correct these. The 30 o inner taper ring was made in four forming passes of wall angle 10 o, 20 o, 30 o and a finishing pass. This approach was chosen to minimize conicity and dishing that would occur if the taper was formed in a single 30 o pass. Further details of rolling parameters for all experiments are given in Table 1. Table 1. Rolling parameters 15 o inner taper 30 o inner taper 15 o outer taper 30 o outer taper Flanged cone Thickness reduction per rev. 1.0% 1.0% 1.0% 1.0% 1.0% Forming roll radius, mm Mandrel radius, mm Preform outer radius, mm Preform wall thickness, mm Preform height, mm Average circumferential constraint roll force, kn Stage 1: 1.01 Stage 2: 0.15 Two outer taper rings were made of taper angle α = 15, 30 o, with the set-up shown in Fig. 4b. In this case the forming roll and constraint rolls lift vertically whilst the radial roll gap is closed. The natural tendency here is for the

4 Christopher J. Cleaver et al. / Procedia Engineering 207 (2017) ring to tilt downwards and this is already constrained by the rolling table so no lipped rolls were used. The locus of point B (Fig 4b.) relative to the mandrel is shown in Fig. 5b. Unlike the inner taper, for both α = 15 and 30 o, the process was carried out in one forming pass, and no corrective steps were required. A single flanged cone ring was made. The upper region of the ring was first reduced from 40mm to a thickness of 15mm, with the forming roll and constraint rolls lifted 18mm above the ring base (Fig. 4c(i)). Then, the mandrel and forming roll were repositioned and the lower region of the ring reduced in thickness from 29 mm to 22.5mm. At this stage, lipped circumferential constraint rolls were again used to prevent ring climbing (Fig. 4c (ii)). Fig. 4. Tooling set-up for (a) inner taper, (b) outer taper and (c) flanged cone 4. Results Fig. 5. Toolpaths for (a) inner taper, (b) outer taper Figure 6 shows the resulting rings and cross-sections. Previously, conical rings had only been realized by IRR because the thinnest wall regions want to increase in radius the most. Here, in all cases, the thinnest wall region

5 1252 Christopher J. Cleaver et al. / Procedia Engineering 207 (2017) either has the same or reduced radius as intended; achieved by significant axial redistribution of material. The outer and inner radial surfaces in the inner taper and outer taper rings respectively have broadly finished parallel to the ring axis, and an almost linear taper is evident on the other surface (Figs. 6a&b). The achieved taper angles for the outer taper were measured at approximately 13 o and 28 o. The flanged cone ring (Fig 6c) was formed successfully: the thinner upper region has tilted, whilst the lower region has finished rectangular and square to the ring axis. Fig. 6. Finished rings and cross-sections (a) inner taper, (b) outer taper and (c) flanged cone (d) outer taper with reduced constraint roll force Comparing the results to the target shapes in Fig. 3 some errors in form can be found. The inner taper rings experienced dishing and unintended conicity at times in the process. This is indicated in Fig. 7a. which plots the shape of the outer radial surface of the 30 o inner taper ring during the third and fourth passes. Early in the third pass the outer profile is parallel to the ring axis but about half way through the pass, the lower section begins to extend circumferentially ahead of the rest of ring. Then, as the mandrel tool lowers to about 16 mm, the increase in radius stops, and material is redistributed axially partially correcting the unintended conicity. On the finishing fourth pass the conicity is completely corrected, though dishing remains: see the lower left of the cross-section in Fig. 6 a(ii). The outer taper rings instead experience underfilling - the wall at the base of the ring reduces in thickness even though it is not in contact with the forming roll tool for most of the process, and so the achieved taper angle is shallower than intended (Fig 5b). Fig 7b. shows the outer profile during the single forming pass for the 30 o outer taper ring: mid-way through the process when the forming roll has lifted vertically by 22mm the taper angle is noticeably shallower than 30 o. As the process continues and the forming roll is lifted further, an unusual effect in ring rolling occurs: at the top surface the ring reduces in circumference. This is thought to be caused by bending deformation akin to the inverse of tube spinning achieved by the array of six circumferential constraint rolls. As a result, the taper angle increases to 28 o at the end of the process. In comparison, in an experiment when the average

6 Christopher J. Cleaver et al. / Procedia Engineering 207 (2017) constraint roll force was a factor of 3 times smaller the resulting taper angle was considerably shallower see Fig. 6d indicating that these constraints play a significant role in influencing the final ring shape. The flanged cone also experiences underfilling during the first forming stage. At the base of the ring, the outer surface is not in contact with the forming roll and yet its thickness reduces from 40 mm to 29 mm - see Fig. 7c. In the second stage, as this area is deliberately thinned it extends circumferentially and a conical form is developed in the upper region. This inevitably indents the inner radial surface see lower left corner of the cross section, Fig. 6c. 5. Discussion Fig. 7. Outer profile shape evolution during process (a) inner taper, (b) outer taper (c) flanged cone This investigation has shown that deliberately conical ring forms can be made by Incremental Ring Rolling (IRR), including for the first time shapes that require significant redistribution of material within the workpiece. This was enabled by both the novel constraint arrangements on the University of Cambridge constrained IRR machine, and the use of corrective tool passes. Further experimentation with both the toolpath and constraining roll force is likely to yield more accurate shapes and verify that expected savings in materials and downstream processing could be realized. A broader investigation could explore the range of geometrical changes possible and practical factors such as cycle time and - through simulation - thermo-mechanical processing conditions required. Acknowledgements The first author s work on this paper was supported by EPSRC grant EP/K018108/1 and Prof. Allwood was supported by EPSRC grant EP/K018108/1. References [1] Hawkyard, J. B., Mouusa, G., (1984) Studies of profile development and roll force in profile ring rolling. Proc. 3 rd Int. Conf. on Rotary Metalwork Processes [2] Allwood, J. M., Kopp, R., Michels, D., Music, O., Öztop, M., Stanistreet, T. F., Tekkaya, A. E., Tiedemann, I. (2005). The Technical and Commercial Potential of an Incremental Ring Rolling Process. CIRP Annals Manufacturing Technology 54(1), [3] Tiedemann, I., Hirt, G., Kopp, R., Michl, D., Khanjari, N. (2007). Material flow determination for radial flexible profile ring rolling. Production Engineering, 1(3), [4] Cleaver, C. J., Allwood, J. M. (2017) Incremental ring rolling with axial and circumferential constraints, CIRP Annals Manufacturing Technology. [5] Seitz, J., Kordtomeikel, F., Hirt, G. (2017) Improvement of the dishing process in ring rolling using conical guide rolls, Production Engineering Research and Development 1/2017

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