JSC EVRAZ NTMK (Nizhny Tagil, Russia):

V. Yu. Rubtsov, Roll Designer of the Rail and Beam Shop, e-mail: Uriylot@mail.ru
V. V. Kurochkin, Roll Designer of the Heavy Section Rolling Shop

Nizhny Tagil Technological Institute of Technology, Nizhny Tagil branch of the Ural Federal University (Nizhny Tagil, Russia):
O. Yu. Shevchenko, Dr. Eng., Head of the Dept. of Metallurgical Technology, e-mail: Shevchenko-OI@ntiustu.ru

The results of modeling the cross-helical rolling process in production of grinding balls are presented in the Deform Integrated 2-D, 3-DV2019 software package using 3-D roll models with a continuously changing pitch and a constant flange width according to the derived pitch change function with the condition of constant volume conservation. The aim of the study is to obtain a model that best matches the real conditions for further investigation of the rolling balls processes using rolls with continuously changing parameters. The simulation results showed details of the rolling process with the definition of parameters, including stress and strain. The simulated process was compared with the results of the experimental rolling conducted using rolls made at the machining center using the same 3-D models. Zones of intense stress are identified, the processes of capture of the blank and separation of the end trim are examined in detail. Reliability of the simulation is confirmed not only by the physical values of the parameters, but also by the high degree of the geometry matching to the obtained ball and the “half”, which proves the possibility of using the simulation programs for rolling balls processes using rolls with continuously changing parameters. The quality of the geometry of the finished ball both in pilot rolling and in the modeling process significantly exceeds the GOST requirements, which proves the application perspectiveness of rolls with continuously changing parameters.

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