0
Research Papers

Flatness Control of the Crossbowed Hot Plate Using Cold Roller Leveling

[+] Author and Article Information
Jae Hyung Seo

R&D Laboratory,
POSCO,
Pohang, South Korea
e-mail: fortran@posco.com

Sang Wook Han

Department of Precision Machining System,
School of Mechanical Engineering,
Pusan National University,
Busan 609-735, South Korea
e-mail: swhan@pusan.ac.kr

Chester J. Van Tyne

Department of Metallurgical and Materials Engineering,
Colorado School of Mines,
Golden, CO 80401
e-mail: cvantyne@mines.edu

Young Hoon Moon

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

1Corresponding author.

Manuscript received February 27, 2018; final manuscript received February 25, 2019; published online March 19, 2019. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 141(5), 051002 (Mar 19, 2019) (8 pages) Paper No: MANU-18-1121; doi: 10.1115/1.4043021 History: Received February 27, 2018; Accepted February 25, 2019

A crossbow is one of the shape defects caused by width differences between the top and bottom plate surfaces. To improve the plate flatness, leveling must be performed to flatten the crossbowed plate prior to the second manufacturing process. Leveling is a process for minimizing shape defects and enhancing the internal stress uniformity in shape-critical applications. As roller levelers mainly correct shape defects across the plate length, the entire plate width must be worked to correct the crossbow. Owing to the high sensitivity of roll positions in the leveler on the plate geometry, a unique leveling machine setup should be determined for flattening the crossbowed plate. As the problem is complicated by the high inherent nonlinearity and sensitivity, the finite element method has been used to simulate numerically the effect of work roll configurations on leveling efficiency. In order to verify the accuracy of numerical simulations, actual leveling experiments were performed using crossbowed plates. Through the analysis, the leveling strategy for increasing the leveling efficiency of crossbowed plates is validated with a high degree of reliability.

FIGURES IN THIS ARTICLE
<>
Copyright © 2019 by ASME
Topics: Rollers , Shapes , Simulation
Your Session has timed out. Please sign back in to continue.

References

Yali, Y., and Herong, J., 2012, “Three Roller Curvature Scotch Straightening Mechanism Study and System Design,” Energy Proc., 16(A), pp. 38–44. [CrossRef]
Moon, Y. H., Kim, D. W., and Van Tyne, C. J., 2008, “Analytical Model for Prediction of Sidewall Curl During Stretch-Bend Sheet Metal Forming,” Int. J. Mech. Sci., 50, pp. 666–675. [CrossRef]
Hemmerich, E., Rolfe, B., Hodgson, P. D., and Weiss, M., 2011, “The Effect of Pre-Strain on the Material Behaviour and the Bauschinger Effect in the Bending of Hot Rolled and Aged Steel,” Mater. Sci. Eng. A, 528, pp. 3302–3309. [CrossRef]
Liu, Z., Wang, Y., and Yan, X., 2012, “A New Model for the Plate Leveling Process Based on Curvature Integration Method,” Int. J. Mech. Sci., 54, pp. 213–224. [CrossRef]
Yi, H. K., Kim, D. W., Van Tyne, C. J., and Moon, Y. H., 2008, “Analytical Prediction of Springback Based on Residual Differential Strain During Sheet Metal Bending,” Proc. Inst. Mech. Eng. C, 222, pp. 117–129. [CrossRef]
Zuo, Q., He, K., Dang, X., Feng, W., and Du, R., 2017, “A Novel Incremental Sheet Bending Process of Complex Curved Steel Plate,” J. Manuf. Sci. Eng., 139, p. 111005. [CrossRef]
Chen, W.-h., Liu, J., Cui, Z.-s., Wang, Y.-j., and Wang, Y.-r., 2015, “A 2.5-Dimensional Analytical Model of Cold Leveling for Plates With Transverse Wave Defects,” J. Iron Steel Res. Int., 22(8), pp. 664–671. [CrossRef]
Laugwitz, M., Seuren, S., Jochum, M., Hojda, S., Lohmar, J., and Hirt, G., 2017, “Development of Levelling Strategies for Heavy Plates Via Controlled FE Models,” Proc. Eng., 207, pp. 1349–1354. [CrossRef]
Achillopoulou, D. V., and Pau, A., 2017, “Characterization of Defects in Plates Using Shear and Lamb Waves,” Proc. Eng., 199, pp. 2001–2007. [CrossRef]
Cho, H.-H., Cho, Y.-G., Kim, D.-W., Kim, S.-J., Lee, W.-B., and Han, H. N., 2014, “Finite Element Investigation for Edge Wave Prediction in Hot Rolled Steel During Run Out Table Cooling,” ISIJ Int., 54(7), pp. 1646–1652. [CrossRef]
Madej, L., Muszka, K., Perzyński, K., Majta, J., and Pietrzyk, M., 2011, “Computer Aided Development of the Levelling Technology for Flat Products,” CIRP Ann. – Manuf. Technol., 60, pp. 291–294. [CrossRef]
Kim, P. H., Chun, M. S., Yi, J. J., and Moon, Y. H., 2002, “Pass Schedule Algorithms for Hot Open Die Forging,” J. Mater. Process. Technol., 130–131, pp. 516–523. [CrossRef]
Behrens, B.-A., El Nadi, T., and Krimm, R., 2011, “Development of an Analytical 3D-Simulation Model of the Levelling Process,” J. Mater. Process. Technol., 211, pp. 1060–1068. [CrossRef]
Li, S., Yin, Y., Xu, J., Hou, J., and Yoon, J., 2007, “Numerical Simulation of Continuous Tension Leveling Process of Thin Strip Steel and Its Application,” J. Iron Steel Res. Int., 14, pp. 8–13. [CrossRef]
Park, K. S., Van Tyne, C. J., and Moon, Y. H., 2007, “Process Analysis of Multistage Forging by Using Finite Element Method,” J. Mater. Process. Technol., 187–188, pp. 586–590. [CrossRef]
Zhao, Y., Wan, X., Gao, L., Kong, Q., and Yu, Z., 2018, “Theoretical Prediction of Sheet Metal Wrinkling Based on the Potential Function Analysis,” J. Manuf. Sci. Eng., 140, 101012. [CrossRef]
Schleinzer, G., and Fischer, F. D., 2001, “Residual Stress Formation During the Roller Straightening of Railway Rails,” Int. J. Mech. Sci., 43, pp. 2281–2295. [CrossRef]
Park, K., and Hwang, S., 2002, “Development of a Finite Element Analysis Program for Roller Leveling and Application for Removing Blanking Bow Defects of Thin Steel Sheet,” ISIJ Int., 42, pp. 990–999. [CrossRef]
Fischer, F. D., Rammerstorfer, F. G., Friedl, N., and Wieser, W., 2000, “Buckling Phenomena Related to Rolling and Levelling of Sheet Metal,” Int. J. Mech. Sci., 42, pp. 1887–1910. [CrossRef]
Chen, J., Qian, J., and Li, S., 2011, “Influence of Hot Leveling and Cooling Process on Residual Stresses of Steel Plates,” Adv. Mater. Res., 168–170, pp. 1130–1135.
Seo, J. H., Van Tyne, C. J., and Moon, Y. H., 2016, “Effect of Roll Configuration on the Leveling Effectiveness of Tail-Up Bent Plate Using Finite Element Analysis,” J. Manuf. Sci. Eng., 138, p. 071004. [CrossRef]
Morris, J. W., Hardy, S. J., and Thomas, J. T., 2002, “Some Fundamental Considerations for the Control of Residual Flatness in Tension Leveling,” J. Mater. Process. Technol., 120, pp. 385–396. [CrossRef]
Bergman, G. C., and Enneking, A. D., 2005, “Displacement-Type Shape Sensor for Multi-Roll Leveler,” U.S. Patent No. 6,857,301, Feb. 22.
Lloyd, T. R., 1947, “Roller Leveler Machine,” U.S. Patent No. 2,429,142, Oct. 14.
Andres, G., 2015, “Shape Measurement System for Roller Levelers,” Master of Science Thesis, Youngstown State University, OH.

Figures

Grahic Jump Location
Fig. 1

Shape defects of plate: (a) crossbow, (b) curl, (c) edge wave, and (d) center buckle

Grahic Jump Location
Fig. 2

Concept of roller-leveling method for crossbowed plate

Grahic Jump Location
Fig. 3

Roll gap concept: (a) δ < 0, (b) δ = 0, and (c) δ > 0

Grahic Jump Location
Fig. 4

Description of entry and exit roll gaps

Grahic Jump Location
Fig. 5

Schematic of roller-leveling simulation for the tail-half crossbow

Grahic Jump Location
Fig. 6

Schematic of roller-leveling simulation for the entire length crossbow

Grahic Jump Location
Fig. 7

Initial plates for FE simulation: (a) tail-half crossbow and (b) entire length crossbow

Grahic Jump Location
Fig. 8

(a) Before and (b) after roller-leveling experiments

Grahic Jump Location
Fig. 9

U-bending for creating the crossbowed plate

Grahic Jump Location
Fig. 10

Laser flatness measuring device

Grahic Jump Location
Fig. 11

Comparisons of roller-leveled shapes for case 1: (a) experiment and (b) FE simulation

Grahic Jump Location
Fig. 12

Comparisons of roller-leveled shapes for case 1: (a) width direction and (b) length direction

Grahic Jump Location
Fig. 13

Comparisons of roller-leveled shapes for case 2: (a) experiment and (b) FE simulation

Grahic Jump Location
Fig. 14

Comparisons of roller-leveled shapes for case 2: (a) width direction and (b) length direction

Grahic Jump Location
Fig. 15

Comparisons of secondary-leveled shape for case 1: (a) experiment and (b) FE simulation

Grahic Jump Location
Fig. 16

Comparisons of secondary-leveled shapes for case 1: (a) width direction and (b) length direction

Grahic Jump Location
Fig. 17

Comparisons of secondary-leveled shapes for case 2: (a) experiment and (b) FE simulation

Grahic Jump Location
Fig. 18

Comparisons of secondary-leveled shapes for case 2: (a) width direction and (b) length direction

Tables

Errata

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In