Research Papers

Effect of Roll Configuration on the Leveling Effectiveness of Tail-Up Bent Plate Using Finite-Element Analysis

[+] Author and Article Information
Jae Hyung Seo

R&D Laboratory,
Pohang 37859, Korea

Chester J. Van Tyne

Department of Metallurgical
and Materials Engineering,
Colorado School of Mines,
Golden, CO 80401

Young Hoon Moon

School of Mechanical Engineering,
Pusan National University,
Busan 609-735, South Korea
e-mail: yhmoon@pusan.ac.kr

1Corresponding author.

Manuscript received May 12, 2015; final manuscript received December 20, 2015; published online March 8, 2016. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 138(7), 071004 (Mar 08, 2016) (7 pages) Paper No: MANU-15-1228; doi: 10.1115/1.4032392 History: Received May 12, 2015; Revised December 20, 2015

The finite-element method (FEM) has been used to numerically investigate the effect of work roll configuration on the leveling effectiveness of tail-up bent plates. Leveling is a process used to minimize shape defects, including flatness imperfections and uniformity of internal stresses in shape-critical applications. Leveling plays an important role in delivering the desired plate shape and meeting the required product standards. To simulate the roller leveling effectiveness of tail-up bent plates, an initially flat plate was plastically bent prior to leveling and was passed through the leveling rolls. Leveling effectiveness was estimated by the vertical displacements of tail-up bent plates with two different roll configurations. One configuration adopts a gradually increasing roll gap, while the other configuration maintains the same roll gap in the first two sets of rolls and gradually increases the roll gap for the later rolls. For comparison purposes, the entry and exit roll gaps of the two roll configurations are set to the same roll gap. To verify the accuracy of the numerical simulations, actual leveling experiments were performed using tail-up bent plates. The results show that the roll configuration significantly influences the leveling effectiveness of the tail-up bent plates. Higher leveling effectiveness is obtained for a leveling configuration that imparts more severe deformation at the earlier leveling stages. Through the analysis, the work roll configuration is determined to be essential to increase leveling effectiveness of tail-up bent plates.

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Fig. 1

Asymmetrical factors of tail-up bending occurrence in rolling

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Fig. 2

Layout of plate rolling and leveling

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Fig. 3

Concept of plate leveling with a roller leveler

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Fig. 4

Concept of roll gap: (a) δ < 0, (b) δ = 0, and (c) δ > 0

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Fig. 5

Two roll configurations with 11 work rolls: (a) case 1 and (b) case 2

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Fig. 6

Two-dimensional finite-element analysis model

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Fig. 7

Configuration of mesh: (a) contact with upper punch and (b) contact with work roll

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Fig. 8

Schematic diagram of leveling experiment with roller leveler and up-bending device

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Fig. 9

Up-bending of plate by using an upper punch

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Fig. 10

Simulation results of roller leveling for case 1: (a) upper punch moves down and plate tail is deformed and (b) plate tail contacts the first work roll

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Fig. 11

Vertical displacement of the flat-plate simulation results for up-bending plate without plastic deformation and up-bent plate with plastic deformation: (a) vertical displacement before leveling and (b) vertical displacement after leveling

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Fig. 12

Results of vertical displacement after leveling simulation: (a) entry roll gap = 11 mm and (b) entry roll gap = 10 mm

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Fig. 13

(a) Tail-up bent plate and (b) roller leveling experiment

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Fig. 14

Comparison of simulated results with experimental results for entry roll gap of 11 mm: (a) case 1 and (b) case 2




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