On a plastic instability criterion for ultra-large radial-axial ring rolling process with four guide rolls

Abstract A dynamic mechanical model is proposed to describe the complexing actions of all the rolls on the ring during the ultra-large radial-axial ring rolling (RARR) process with four guide rolls. Based on the model, the calculation models for bending moment and normal stress at any section of the ring are deduced by force method. If the maximum section bending normal stress exceeds the yield stress of the ring materials, the ring will be distorted thus leading to the instability of the RARR process. According to this, a plastic instability criterion for the ultra-large RARR process with four guide rolls is developed, based on which a mathematical model to calculate the critical guide force for avoiding plastic instability of ring is obtained. The influence rule of the position of guide roll on the dangerous ring section of plastic instability is revealed, from which it is found the dangerous ring section mainly appears at the radial and axial deformation regions and the contact positions of the guide rolls and ring. The optimized layout of guide roll around the ring in favor of stability is determined to be about α1=61° and α2=119°. The plastic instability criterion is proven to be reliable from the aspects of the critical guide force, the section bending moment and normal stress and the dangerous ring section of plastic instability. Intelligent simulation case studies for the RARR process of ultra-large aluminum alloy ring indicate that the stable forming of the process can be effectively realized by regulating the guide force based on the plastic instability criterion. This work could provide a valuable guidance for the control of guide rolls and the optimization of the ultra-large RARR process with four guide rolls.