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1

Numerical Modelling of a Rotary Compression Test on a Cylindrical Specimen

Pater Zbigniew

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no 4

23--32

EN

This paper reviews studies on the modelling of the Mannesmann effect, which leads to the formation of an axial crack in parts formed by cross and skew rolling. This effect also occurs in the rotational compression (RC) test of a cylindrical specimen, which is used to determine the critical damage value. RC tests were carried out under laboratory conditions at the Lublin University of Technology on C45 steel specimens formed at 950°C. Based on the tests, the crack propagation was presented as a function of the progress of rotational compression, measured by the length of the deformation path. The RC tests were numerically modelled in Forge® using four ductile fracture criteria. The effectiveness of the Mannesmann effect modelling was evaluated by comparing the numerically predicted cracks with the experimentally determined ones. In addition, the influence of an occurring axial crack on the stress state in the forming specimen was analysed.

2

Numerical and experimental investigations on Mannesmann effect of nickel‑based superalloy

Zhang Zhe, Liu Dong, Man Tongchi, Li Nan, Yang Yanhui, Pang Yuhua, Wang Jianguo

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 3

art. no. e133

EN

The preparation of nickel-based superalloy tubes by rotary tube piercing (RTP) process is still difficult due to the Mannesmann effect (central cracking phenomenon) has not been clarified. The combinations of numerical analysis and experiment verifications method were adopted in the study. The critical parameters for central cracking were determined by experiments. It was found that the evolution process of central cracking for nickel-based superalloy includes voids nucleation, growth and aggregation. Based on the obtained critical parameters, the evolutions of stress, strain, strain rate, temperature and damage were discussed by numerical simulation. By comparing the experiment results and simulation results, the Normalized Cockcroft and Latham (NCL) model was determined as the most suitable model. Considering the influences of temperature and strain rate on the damage threshold, the NCL model of Inconel 718 alloy was established by high-temperature tensile test. Based on the above results, it is found that the maximum shear stress promotes the plastic deformation, which provides necessary conditions for the generation of defects, and the maximum principal stress induces the generation of voids and expansion of micro-cracks, which directly leads to the central cracking. The essence of central cracking is ductile fracture under tensile stress.

3

Experimental and numerical analyses of 45 steel during three dimensional severe plastic deformation (3D-SPD)

Pang Yuhua, Lin Pengcheng, Sun Qi, Zhang Zhe, Liu Dong

Archives of Civil and Mechanical Engineering

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2020

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Vol. 20, no. 4

71--81

EN

Due to the limitation of huge forming load, inhomogeneity of plastic deformation, and small volume of deformation region, it is difficult to prepare bulk ultra-fine grains material (UFGM) with industry size by the existing severe plastic deformation (SPD) methods. In this study, a novel SPD method, namely 3D-SPD, was proposed. By establishing finite element model, the distribution of material flow, restraining to Mannesmann effect, and comparison of load were discussed. Based on the self-developed rolling mill, the corresponding experiments were conducted. The experimental results reveal that the buck ultra-fine grains material of 45 steel was obtained under the condition of feed angle 21°, cross angle 15°, cone angle 5°, reduction rate 50%, and roll speed 30 rpm. The average grain size was refined from 46 to 0.8–4 μm. The tensile test results indicate that the yield strength and tensile strength of the rolled bar were significantly improved.

4

Physical Simulation of the Mannesmann Effect in the Rolling Process

Wójcik Ł., Pater Z.

Archives of Metallurgy and Materials

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2019

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Vol. 64, iss. 4

1369--1375

EN

The study presents the results of laboratory testing of the phenomenon of cracking in the process of cross rolling. A new method of determining the critical value of the damage function was developed, in which a disc-shaped sample is subjected to rotational compression in a channel. In this method the Mannesmann effect was used. The laboratory tests were conducted for C45, 50HS and R260 grade steel in the temperature range 950°C-1150°C. In order to research various methods of simulating the phenomenon of cracking in the process of cross rolling, physical modelling was also employed. The model material was commercial plasticine, cooled to the temperature 0°C-20°C. Comparing the test results for both the real and model material allowed one to determine the range of the forming temperature for the model material, in which the cracking process is similar to the case of the real material.