Efficient formability in Radial-Shear Rolling of A2024 aluminum alloy with screw rollers

Abstract

The Radial-Shear Rolling (RSR) process, commonly utilizing traditional conical rollers, encounters challenges in achieving optimal deformation in high-strength aluminum alloy A2024, vital for aerospace applications due to its exceptional strength-to-weight ratio. This study explores the potential of screw rollers to enhance RSR efficiency for A2024 aluminum, aiming to evaluate their impact on microstructure, mechanical properties, and key deformation parameters (force, temperature) compared to conical rollers. Employing a combined approach of finite element simulations and experiments with force analysis, the study assesses the effects of screw rollers in a two-pass RSR process. The findings reveal significant advantages with screw rollers, achieving a 15 % increase in equivalent strain compared to conical rollers, indicating enhanced material formability. Consistent temperature distribution across roller types ensures stable processing conditions. Screw rollers also demonstrate a 9 % reduction in force required during the second rolling pass, potentially reducing equipment load demands and enabling higher compression per pass for improved process efficiency. Additionally, a more uniform microhardness distribution suggests consistent mechanical properties with screw rollers compared to conical ones. These results highlight the potential of screw rollers to optimize RSR of A2024 aluminum, offering improved plastic deformation efficiency, temperature control, and potentially lower equipment loads. This advancement holds promise for a more efficient and cost-effective RSR process in producing high-quality A2024 aluminum components for aerospace and other demanding applications.