Process Window and Repeatability of Thermomechanical Tangential Ring Rolling

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a final calibration step via cold forming are combined into one single step. The reduction of process steps and the reduced number of heating cycles present opportunities for improved energy efficiency compared to traditional processes. Based on a series of experiments, this paper aims at showing the potential of this new process in terms of obtainable hardness and microstructure. The influence of the active cooling system and the rolling feed is demonstrated. They are identified as essential with regard to both the geometry and the microstructural properties of the produced part. Finally, the repeatability of the process is analyzed, and potential disturbances are identified and ranked.

Automated summary

International objectives for resource and energy efficiency necessitate new manufacturing processes, like the proposed thermomechanical tangential profiled ring rolling process, which combines rapid cooling and cold forming into a single step. This reduction in process steps and heating cycles offers improved energy efficiency compared to traditional methods. Through a series of experiments, this paper demonstrates the potential of the new process in terms of achievable hardness and microstructure, with the cooling system and rolling feed identified as essential factors. Furthermore, the repeatability of the process is analyzed, and potential disturbances are identified and ranked.