Research of energy-power parameters during powder wire flattening

A mathematical model of stress–strain behavior is developed for the process of powder wire flattening. Modeling was based on a partition of the deformation zone at a set of elementary volumes and a joint solution of the plasticity condition for porous materials and the equation of static equilibrium of forces within the elementary volume. The proposed mathematical model takes into account the real character of geometric parameter distributions as well as the complex of mechanical properties and conditions of contact friction along the length of the deformation zone. A distinctive feature of this model is an accounting for shell deformation in the deformation zone. This allowed us to define more precisely the plastic deformation zone and take into account the effect of shell bending on the energy-power parameters of the process. The experiments confirmed the validity of the assumptions and the shell influence on the process parameters. The proposed modeling approach provides the possibility to predict and optimize the parameters of an electrode material made by pressure working of powder wire. The derived results of the numerical simulation may be useful in improving the efficiency of the subsequent deposit welding operations.

[1]  M. Ramakrishnan,et al.  Application of submerged arc welding technology with cold wire addition for drum shell long seam butt welds of pressure vessel components , 2013 .

[2]  R. K. Dube,et al.  Processing and Characterization of Cu-Al-Ni Shape Memory Alloy Strips Prepared from Prealloyed Powder by Hot Densification Rolling of Powder Preforms , 2011 .

[3]  H. Fujii,et al.  High transport critical current density obtained for powder-in-tube-processed MgB2 tapes and wires using stainless steel and Cu–Ni tubes , 2001 .

[4]  F. Lambiase,et al.  Experimental and Finite Element Investigation of Roll Drawing Process , 2012, Journal of Materials Engineering and Performance.

[5]  Joanna Przondziono.  Flattening of narrow and thin stainless steel strips , 2008 .

[6]  M. E. Karabin,et al.  Evolution of porosity during thin plate rolling of powder-based porous aluminum , 1994 .

[7]  E. P. Gribkov,et al.  Investigation of the process of drawing flux-cored wire for welding copper to steel , 2012 .

[8]  O. A. Katrus,et al.  Effects of the surface roughness of rolls on the powder rolling process , 1974 .

[9]  M. Woch,et al.  Bimetallic wires: technology for their mechanical cold cladding and functional properties , 2011 .

[10]  M. R. Toroghinejad,et al.  Manufacturing of High-Performance Al356/SiCp Composite by CAR Process , 2011 .

[11]  Alexander V. Perig,et al.  Equal channel angular extrusion of soft solids , 2010 .

[12]  E. P. Gribkov,et al.  A mathematical model of the process of rolling flux-cored tapes , 2015 .

[13]  P. Guigon,et al.  Correlation between powder-packing properties and roll press compact heterogeneity , 2003 .

[14]  Susumu Shima,et al.  Experiment on metal powder compaction by differential speed rolling , 2001 .

[15]  P. A. Gavrish,et al.  Improving the technological conditions of drawing flux-cored welding wires , 2014 .

[16]  Saeid Soltanian,et al.  Fabrication and critical current density in 16-filament stainless steel/Fe/MgB2 square wire , 2002 .

[17]  A. K. Tieu,et al.  A study on the cross-sectional profile of flat rolled wire , 2008 .

[18]  P. Guigon,et al.  Roll press design—influence of force feed systems on compaction , 2003 .

[19]  M. B. Shtern,et al.  Stress-strain state of powder being rolled in the densification zone , 1983 .

[20]  Huang-Chi Tseng,et al.  An analysis of the formability of aluminum/copper clad metals with different thicknesses by the finite element method and experiment , 2010 .

[21]  M. B. Shtern,et al.  Stressed-strained state of powder being rolled in the densification zone. I. Mathematical model of rolling in the densification zone , 1983 .

[22]  Sergej Hloch,et al.  Determination of layer thickness in direct metal deposition using dimensional analysis , 2013 .

[23]  Alexander V. Perig,et al.  ECAP process improvement based on the design of rational inclined punch shapes for the acute-angled Segal 2θ-dies: CFD 2-D description of dead zone reduction , 2015 .

[24]  N. R. Chitkara,et al.  Working Pressure, Deformation Modes and Fracture in Open-Piercing of Cylindrical Disks Made of Compacted Sintered Aluminium Powder , 2001 .

[25]  Sumesh Narayan,et al.  Influence of carbon content on workability behavior in the formation of sintered plain carbon steel preforms , 2013 .

[26]  A. S. Kolpakov,et al.  Contact stresses in the deformation zone and average pressure during asymmetric rolling of metal powders , 2013, Powder Metallurgy and Metal Ceramics.

[27]  Mohsen Kazeminezhad,et al.  An experimental investigation on the deformation behavior during wire flat rolling process , 2005 .

[28]  Zhen Xing Zheng,et al.  Experimental and Numerical Modeling for Powder Rolling , 2012 .

[29]  Alexander V. Perig,et al.  Research into the process of producing powder tapes , 2015 .

[30]  Alexander V. Perig,et al.  CFD SIMULATION OF ECAE THROUGH A MULTIPLE-ANGLE DIE WITH A MOVABLE INLET WALL , 2014 .

[31]  Meftah Hrairi,et al.  Modeling the powder compaction process using the finite element method and inverse optimization , 2011 .

[32]  Yuichi Nakamura,et al.  Phase formation mechanism and properties of Ag-sheathed (Bi,Pb)-2223 tapes prepared by two-powder method , 2003 .

[33]  Harpreet Singh,et al.  Composite fabrication using friction stir processing—a review , 2012 .

[34]  R. Chandramouli,et al.  Influence of material flow constraints during cold forming on the deformation and densification behaviour of hypoeutectoid P/M steel ring preforms , 2007 .

[35]  Kishore,et al.  Influence of friction during forming processes—a study using a numerical simulation technique , 2009 .

[36]  O. A. Katrus,et al.  Compressibility of heterogeneous powder mixtures in rolling , 1973 .

[37]  Mw W. Fu,et al.  A review on the state-of-the-art microforming technologies , 2013 .

[38]  Hamid Reza Karimi,et al.  Instrumentation and modeling of high-pressure roller crusher for silicon carbide production , 2012 .

[39]  Faycal Benyahia,et al.  Diametral compression test: validation using finite element analysis , 2011 .

[40]  Carpóforo Vallellano,et al.  Analysis of deformations and stresses in flat rolling of wire , 2008 .

[41]  Alexander V. Perig,et al.  CFD 2D simulation of viscous flow during ECAE through a rectangular die with parallel slants , 2014 .

[42]  A. V. Stepanenko,et al.  Geometric and power parameters of the metal powder rolling process. I. Boundaries of the seat of deformation and stress field in the lag and forward slip zones , 1990 .

[43]  Yoshimi Murata,et al.  Experimental Analysis of Metal Flow and Strain Distribution in Rolling of Sn-Pb Powder , 2009 .

[44]  A. V. Stepanenko,et al.  Geometric and energy-force parameters of the process of rolling of metal powders II. The rolling power, moment, and contact stresses and distribution of density in the area of deformation , 1991 .

[45]  E. P. Gribkov,et al.  Stressed state and kinematics in the rolling of powder materials on a metal substrate , 2000 .

[46]  G. A. Vinogradov,et al.  Investigation of specific pressure, specific friction, and the coefficient of friction during metal powder rolling , 1963 .

[47]  K. Osakada,et al.  Analysis of the forming process of sintered powder metals by a rigid-plastic finite-element method , 1987 .

[48]  Amir R. Khoei,et al.  Genetic algorithm-based numerical optimization of powder compaction process with temperature-dependent cap plasticity model , 2013 .