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1
Content available Determination of Critical Damage Function Values of CW008A Copper and S355 Steel in Tensile and Torsion Tests
Walczuk-Gągała Patrycja, Pater Zbigniew, Wójcik Łukasz, Lis Konrad
Advances in Science and Technology. Research Journal
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2023
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Vol. 17, no 2
173--180
EN
The article describes the problem of material fracture in metal forming processes. It describes and compares the values of damage functions obtained in classical tensile and torsion tests of two materials, i.e. CW008A copper and S355 steel under cold forming conditions. The presented research methodology includes experimental tests and numerical simulation carried out using Simufact.Forming v.15 software. The damage values were analysed according to various criteria, including the growth and coalescence of micro cracks (Rice&Tracey, Oyane, Argon), the initiation and development of ductile cracking in forming processes (Freudenthal, Cockroft-Latham, Brozzo, Oh) and using extended phenomenological models based on the history of stress triaxiality (Ayada) or the mean and equivalent stress (Zhan). The conducted tests showed that the values of the damage function depend on: the calibration test, the material grade and the geometry of the specimen.
2
Content available remote Numerical and experimental study on forming preforms in a CNC skew rolling mill
Pater Zbigniew, Tomczak Janusz, Bulzak Tomasz, Walczuk-Gągała Patrycja
Archives of Civil and Mechanical Engineering
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2022
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Vol. 22, no. 1
art. no. e54, 2022
EN
This paper relates to a study on the formation of elongated preforms in a CNC skew rolling mill. First, a numerical analysis was performed to investigate forming processes for three different parts: a scraper, a connecting rod, and a hook. The shapes and dimensions of preforms were designed, and rolling and closed-died forging processes for producing these parts were simulated numerically. Distributions of temperature, effective strain and damage function were determined for rolled preforms. Loads and torques in the rolling process were measured. It was found that the forming process of preforms performed in a CNC skew rolling mill was characterized by relatively low force parameters in relation to the dimensions of formed parts. Numerical simulations of the forging process showed that all forged parts had the required shape, which indicates that the preforms were designed correctly. Following the numerical analysis, experiments were performed in which the preforms were rolled under laboratory conditions (in a scale of 1:2). Experimental results demonstrated that the rolled parts had no internal defects (cracks) and were characterized by high dimensional accuracy.
3
Content available Conception of Hollow Axles Forming by Skew Rolling with Moving Mandrel
Pater Zbigniew, Walczuk-Gągała Patrycja
Advances in Science and Technology. Research Journal
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2021
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Vol. 15, no 3
146--154
EN
The article presents a conception of manufacturing a hollow axle using three skewed rolls moving at the same rotating speed, axially moving chuck and a moving mandrel. The outer shape of the axle is obtained as a result of combining the radial feed of the rolls with axial feed of the chuck. The hole in the axle, however, is obtained as a result of the mandrel acting on the workpiece while moving along with it. In order to assess the correctness of the presented concept of forming, a numerical simulation was performed in Simufact.Forming commercial software. The results of the simulation confirmed that the applied method allows one to manufacture large-size hollow axles. Moreover, information on force parameters of the forming process, which can be used for designing an industrial rolling mill was obtained.
4
Content available Numerical Analysis of the Cross-Wedge of a Hollow Rail Axle
Pater Zbigniew, Lis Konrad, Walczuk-Gągała Patrycja
Advances in Science and Technology. Research Journal
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2020
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Vol. 14, no 1
145--153
EN
The article presents an innovative method of manufacturing hollow rail axles using three combined wedge rolls. The proposed solution was evaluated using numerical simulation. Two cases of forming, differing in the wall thickness of the billet, were analysed. The geometry of the formed axles, distributions of the effective strain, temperature and damage function were presented. Moreover, the changes to the forces and torques acting on each roll were presented.
5
Content available Determination of the Value of the Damage Function in 1050A Aluminium Alloy
Walczuk-Gągała Patrycja, Pater Zbigniew, Wójcik Łukasz
Advances in Science and Technology. Research Journal
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2020
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Vol. 14, no 2
49--55
EN
The article presents the problem of material cracking in metal forming processes. The authors describe and compare the values of damage obtained in classic tensile and compression tests as well as rotational compression of 1050A aluminium alloy in cold working conditions. The presented research methodology contains experimental tests as well as a numerical simulation conducted in Simufact.Forming v.15. An analysis of the damage values was calculated according to the normalised Cockcroft-Latham criterion. The research conducted showed that the damage value in the rotational compression test is greater than the values obtained by the means of other tests.
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