A modified slab method approach for an efficient ring rolling torque and energy evaluation in presence of fishtail effect

Ring rolling (RR) is a key process for manufacturing seamless rings, yet its complex thermo-mechanical behavior often necessitates expensive experiments or FEM analyses. This study proposes an analytical methodology for predicting torque and energy in RR while explicitly accounting for the fishtail effect, a lateral deformation significantly influencing process mechanics. The approach integrates a slab-based mechanistic model with a regression law relating fishtail deformation to the kinematic ratio between mandrel feed and ring speed. Validation against FEM simulations on AISI 1045 rings demonstrates improved accuracy over conventional fishtail-neglecting models, enabling efficient early-stage process design and optimization.