Development of the Technology of Various Large Bodies Manufacturing Based on Combined Methods of Deformation

Abstract:

Metallurgy and heavy engineering construction, which are considered the most energy-intensive industries, place great focus on complex shaped thick-gage plate metal items of equipment with wall thickness exceeding 40 mm and diameter/width of up to 4000 mm. Such items of equipment include large machine parts manufactured by means of hot plate stamping, such as bodies of rotation (for example, the segment of the radial surface of converter shell, the bottom part of degassing unit, etc.) utilized as pressure-operated devices, vessels, tanks and other facilities by metallurgical, petrochemical, oil and gas, and nuclear industries. Presently known manufacturing methods of such items of equipment, for instance, stamping methods, have a number of technological problems. In the present paper, creation and development of the theory and technology of manufacturing different large bodies based on the combination of plate rolling and stamping processes, as well as the combination of asymmetric rolling and plastic bending processes, are proposed. The goal was to develop a cost-effective technology of producing large-size bodies of rotation in the conditions of a thick-plate mill. The rolling of the package forms the basis of the first stage of the new process. The package consists of the upper (punch) base, the lower (matrix) base, and the blank plate situated between them. The economic benefit from installing the developed technology based only on the combination of asymmetric rolling and plastic bending processes was more than 1 million dollars. Casings on two converters were produced and installed in the oxygen-converter plant.

• Periodical: Key Engineering Materials (Volume 716)
• Pages: 659-666
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.716.659
• Online since: October 2016
• Authors: Alexander Pesin*, Ernest Drigun, D.O. Pustovoytov, Ilya Pesin
• Keywords: Bending, Combined Methods, Large Bodies of Rotation, Plate Rolling, Stamping

References

[1] W.J. Kim, B.G. Hwang, M.J. Lee, Y.B. Park, Effect of speed-ratio on microstructure, and mechanical properties of Mg-3Al-1Zn alloy, in differential speed rolling. J. Alloy. Compd. 509 (2011) 8510-8517.

DOI: 10.1016/j.jallcom.2011.05.063

[2] G. Angella, Jahromi B. Esfandiar, M. Vedani, A comparison between equal channel angular pressing and asymmetric rolling of silver in the severe plastic deformation regime, Mater. Sci. Eng. A. 559 (2013) 742-750.

DOI: 10.1016/j.msea.2012.09.018

[3] Saeed Tamimi, João P. Correia, Augusto B. Lopes, Said Ahzi, Frederic Barlat, Jose J. Gracio, Asymmetric rolling of thin AA-5182 sheets: Modeling and experiments. Mater. Sci. Eng. A. 603 (2014) 150-159.

DOI: 10.1016/j.msea.2014.02.048

[4] X. Gong, H. Li, S.B. Kang, J.H. Cho, S. Li, Microstructure and mechanical properties of twin-roll cast Mg-4. 5Al-1. 0Zn alloy sheets processed by differential speed rolling, Materials and Design. 31(3) (2010) 1581-1587.

DOI: 10.1016/j.matdes.2009.09.021

[5] Hamad, Kotiba, Bong Kwon Chung, Young Gun Ko, Effect of deformation path on microstructure, microhardness and texture evolution of interstitial free steel fabricated by differential speed rolling, Materials Characterization (2014).

DOI: 10.1016/j.matchar.2014.05.019

[6] А.М. Pesin; V.М. Salganik; G.A. Kunitsin, The development and application of the processes of asymmetric rolling / Proceedings of the International Conference METEC 2003. Dusseldorf. Germany. (2003).

[7] A. Pesin, V. Salganik, E. Trahtengertz, M. Cherniahovsky, V. Rudakov, Mathematical modeling of the stress-strain state in asymmetric flattening of metal band, J. Mater. Process. Tech. 125-126 (2002) 689-694.

DOI: 10.1016/s0924-0136(02)00353-9

[8] A. Pesin, Practical results of modeling asymmetric rolling, Steel in Translation. 33 (2003) 46-49.

[9] A.M. Pesin., New solutions on basis of non-symmetric rolling model. Stal, (2003) 66-68.

[10] Zuo Fang-qing, Jiang Jian-hua, Shan Ai-dang, Fang Jian-min, Zhang Xing-yao, 2008. Shear deformation and grain refinement in pure Al by asymmetric rolling. Transactions of Nonferrous Metals Society of China 18, 774-777.

DOI: 10.1016/s1003-6326(08)60133-8

[11] Ji Y.H., Park J.J., Kim W.J., Finite element analysis of severe deformation in Mg-3Al-1Zn sheets throughout differential-speed rolling with a high speed ratio. Mater. Sci. Eng. A. 454-455 (2007) 570-574.

DOI: 10.1016/j.msea.2006.11.076

[12] M. Sverdlik, A. Pesin , D. Pustovoytov. Theoretical basis and technology development of the combined process of asymmetric rolling and plastic bending. Advanced Materials Research (2012).

DOI: 10.4028/www.scientific.net/amr.586.259

[13] Y.H. Ji, J.J. Park, Development of severe plastic deformation by various asymmetric rolling processes. Mater. Sci. Eng. A. 499 (2009) 14-17.

DOI: 10.1016/j.msea.2007.11.099

[14] V.A. Demin, Development of a method of the plate stamping processes designing on the basis of forecasting of technological failure: D. Sc. Thesis. Moscow (2003) 342.

[15] H. Karbasian, A.E. Tekkaya, A review on hot stamping, J. Mater. Process. Tech. 210 (2010) 2103-2118.

DOI: 10.1016/j.jmatprotec.2010.07.019

[16] А. Pesin, V. Salganik, E. Drigun, D. Chikishev, Device for asymmetrical rolling metal plate, RU Patent 38646 (2004).

[17] А. Pesin, V. Salganik, E. Drigun, D. Chikishev, Device for asymmetrical rolling metal plate, RU Patent 2254943 (2005).

[18] А. Pesin, V. Salganik, D. Chikishev, Device for asymmetrical rolling metal plate, RU Patent 54831 (2006).

[19] А. Pesin, D. Chikishev, S. Blinov, Device for measuring a radius of curvature of the cylindrical surface of large parts, RU Patent 56592 (2006).

[20] А. Pesin, D. Chikishev, S. Blinov, D. Pustovoytov, Device for asymmetrical rolling metal plate, RU Patent 87649 (2009).

[21] M Sverdlik, A. Pesin , D. Pustovoytov. Theoretical basis and technology development of the combined process of asymmetric rolling and plastic bending. Advanced Materials Research (2012).

DOI: 10.4028/www.scientific.net/amr.586.259

[22] A. Pesin, E. Drigun, D. Pustovoytov, I. Pesin. Study of different large bodies manufacturing based on combined methods of deformation, MATEC Web of Conferences. 26 03007 (2015).

DOI: 10.1051/matecconf/20152603007

[23] A. Pesin, E. Drigun, D. Pustovoytov, I. Pesin. Technology development of large-size bodies manufacturing from thick plate materials based on combined methods of deformation. Key Engineering Materials. 685 (2016) 375-379.

DOI: 10.4028/www.scientific.net/kem.685.375