Forming characteristics and mechanism of double-roll rotary forging for large-diameter and thin-walled metal discs

Double-roll rotary forging is an emerging plastic forming technology based on forging. Owing to the advantages of labor saving, small eccentric load, low noise and vibration, good uniformity, high surface quality, material it very promising for fabrication large-diameter thin-walled disc. To date, a few relevant researches double-roll metal discs have been reported, mechanisms process disc workpieces remain uninvestigated. Herein, 3D rigid-plastic finite element model (FEM) established simulate disc; four geometric features appear in process: “mushroom” shape, “upper drum” “drum shape” “lower shape. Equivalent stress, equivalent strain, temperature field these shapes are analyzed, mechanism revealed. The reliability accuracy FEM verified through experiments, shape occur consistent with simulation. research results provide valuable guidelines better understanding discs.