Research on Filling Limit of Profile Ring Rolling on Circumferential Surface

In the present study, we designed a ring rolling preform for producing a ringed product with a grooved outer circumferential surface. One of the most common defects in the profile of a ring rolling process is unfilling, which occurs when the deformation amount of product is small or the depth of the groove in the outer surface is large. To prevent unfilling, the deformation amount should be increased, or the preform should be designed to be very similar to the final profile. A filling limit equation for eliminating defects from products is proposed based on the aspect ratio and forging ratio. The filling limit equation was derived using the results of finite element analyses for four cases. The validity of the proposed method was tested by comparing the predication of the filling limit equation with the results of a full-size ring rolling operation, and the production stability was verified with mass production test. Keywords— Finite Element Analysis, Filling limit equation, Preform design, Profile ring rolling, Cost saving.