ANALYSIS OF THE INTERNAL DEFECTS IN PARTS MANUFACTURED BY THE CROSS WEDGE ROLLING PROCESS.

• Grant number: 08/05249-9
• Support Opportunities: Scholarships in Brazil - Post-Doctoral
• Start date: August 01, 2008
• End date: July 31, 2011
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Sergio Tonini Button
• Grantee: Mário Luiz Nunes da Silva
• Host Institution: Faculdade de Engenharia Mecânica (FEM). Universidade Estadual de Campinas (UNICAMP). Campinas , SP, Brazil

Abstract

Cross-wedge rolling (CWR) is a metal forming process in which wedge shaped tools are assembled to rollers, and concave or convex plates. Parts produced by this process are usually stepped shafts and pins for the automotive industry. Despite the advantages of this process associated with high productivity and reduction of raw materials, the formation of an internal defect, called Mannesmann, requires a careful inspection of the rolled parts. This defect has its origin in the center of the rolled pieces and its causes are not yet fully identified. Based on the finite element method, numerical simulations of the CWR process in three dimensions will be studied using two commercial programs: MSC Superform and Deform 3D, in order to analyze the influence of some geometric and process variables on the formation of this that is considered the main defect of the process. Tests in an experimental equipment available in the Mechanical Forming Laboratory of the Mechanical Engineering Faculty will also be performed covering the same variables cited for the simulation. The data from these tests will be confronted with simulations to determine the possible causes of the defect and if possible, to indicate the ideal processing conditions to avoid it.