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<p>Large-diameter axially thin-walled metal rings (LDATWMR) are critical structural components in launch vehicles, nuclear submarines, and nuclear power equipment and are particularly well-suit to the double-roller rotary forging (DRRF). However, during the DRRF of LDATWMR, excessive diameter-to-thickness ratios can induce elastic-plastic instability, leading to forming failure. To address this, an analytical model capable of predicting such instability was developed. FE simulation and experiments subsequently validated the reliability of the analytical model, and confirmed the feasibility of DRRF for LDATWMR. Using the validated FE model, the influence of key process parameters—including the initial ring’s outer-to-inner diameter ratio and thickness, upper die rotational velocity, lower die feed velocity, and friction coefficient between the upper die and the ring on the warping of the LDATWMR was investigated. Based on the simulation and experiment results, effective warpage control strategies for the DRRF process were proposed.</p>

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Instability and warping mechanism of double-roller rotary forging of large-diameter thin-walled metal rings

  • 期刊论文

  • 发表日期：

    2026年4月30日

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  • Zhongquan Yu,
  • Huanqi Weng,
  • Mingchao Chen,
  • Yingping Qian,
  • Chundong Zhu,
  • Yijie Cai

摘要

Large-diameter axially thin-walled metal rings (LDATWMR) are critical structural components in launch vehicles, nuclear submarines, and nuclear power equipment and are particularly well-suit to the double-roller rotary forging (DRRF). However, during the DRRF of LDATWMR, excessive diameter-to-thickness ratios can induce elastic-plastic instability, leading to forming failure. To address this, an analytical model capable of predicting such instability was developed. FE simulation and experiments subsequently validated the reliability of the analytical model, and confirmed the feasibility of DRRF for LDATWMR. Using the validated FE model, the influence of key process parameters—including the initial ring’s outer-to-inner diameter ratio and thickness, upper die rotational velocity, lower die feed velocity, and friction coefficient between the upper die and the ring on the warping of the LDATWMR was investigated. Based on the simulation and experiment results, effective warpage control strategies for the DRRF process were proposed.