Realistic Modelling of the Tool Kinematics of Radial-Axial Ring Rolling Machines in Finite Element Simulation

摘要

For simulating metal forming processes by means of Finite Element programs it is required to define all tool motions beforehand. This is one of the major difficulties of the conventional Finite Elements Analysis (FEA) for simulating ring rolling processes, since in reality the motions are controlled by closed-loop control systems according to current sensor values. A solution is given by integrating control algorithms into the Finite Element model. In a previous publication the authors have presented a method in which the algorithms of an industrial control system of ring rolling machines are coupled with the Finite Element model. Although this approach enables modelling with realistic kinematic conditions, it has the major drawback that the algorithms of the used control are not disclosed to the users. Hence, it will not be possible to modify the controller for new processes and process optimization. In this paper, therefore, a set of reasonable and simple control algorithms is introduced, which can be used as basis for further improvements of existing control algorithms of ring rolling. The developed approach considers all relevant sensors of ring rolling machines. Using the developed model a ring rolling simulations is carried out and compared to the corresponding experimental results. The results show very good agreement in terms of the ring geometry and the machine loads.