• 한국정밀공학회지
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• 제21권9호
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• pp.95-102
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• 2004

A flexible incremental roll forming process has been developed by adopting the advantages of the incremental forming process and the roll forming process: i.e., inherent flexibility of the incremental forming process and continuous bending deformation of the roll forming process. It has an adjustable roll set as a forming tool composed of one upper center roll and two pairs of lower support rolls, which plays a key role during forming process. Through the experiments based on the various combinations of process parameters, it is shown that the incremental roll forming process is so effective as to manufacture various doubly curved sheet metals including concave-convex combination shapes in which there exists a line of inflection. The proposed relationship of the experimental parameters and the radius of curvature of the formed sheet boundary is found to be useful in prediction and control of the final shape.

• 소성∙가공
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• 제25권6호
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• pp.390-395
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• 2016

GDI fuel rail is component of GDI system which directly fuel with high pressure in the engine combustion chamber. And it is required to high strength and dimensional accuracy. Multi roll-die drawing process consists of the idle roll-die and drawing die in tandem. In the course of drawing with roll-die, deformation takes place between the idle roller pair or pairs. The friction force decreases with the idle roll-die, enabling the reductions to be risen in one step. In this study, the caliber of 4-roll was designed into pass schedule that made the draw force at the exit of the drawing die be equal. In order to compensate for over-filling area, the roll caliber was modified using the result of FE-analysis. The results of FE-analysis and experiment show that the proposed design method can be used to effectively design the multi roll-die process, leading to an accurate shape and correct dimensions of the final within an allowable tolerance of ${\pm}0.08mm$. Furthermore, the productivity was evaluated by comparing with multi roll-die drawing process and conventional multi shape drawing process. The result was confirmed that it has an efficiency of about 2 times than conventional process in terms of time.

• 소성∙가공
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• 제29권5호
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• pp.282-289
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• 2020

Flexible roll forming is an advanced sheet-metal-forming process that allows the production of parts with various cross-sections. During the flexible process, material is subjected to three-dimensional deformation such as transverse bending, inhomogeneous elongations, or contraction. Because of the effects of process variables on the quality of the roll-formed products, the approaches used to investigate the roll-forming process have been largely dependent on experience and trial- and-error methods. Web-warping is one of the major shape defects encountered in flexible roll forming. In this study, an SVR model was developed to predict the web-warping during the flexible roll forming process. In the development of the SVR model, three process parameters, namely the forming-roll speed condition, leveling-roll height, and bend angle were considered as the model inputs, and the web-warping height was used as the response variable for three blank shapes; rectangular, concave, and convex shape. MATLAB software was used to train the SVR model and optimize three hyperparameters (λ, ε, and γ). To evaluate the SVR model performance, the statistical analysis was carried out based on the three indicators: the root-mean-square error, mean absolute error, and relative root-mean-square error.

• 소성∙가공
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• 제19권2호
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• pp.101-106
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• 2010

CB100 is one of the channel type products in the steel beam. In this study, rolling process of CB100 is analyzed by 3D FEM simulation and rolling process. FEM simulation result is compared with rolling process data. Also the intermediate & finishing roll stress analysis is carried out and the suitability of the roll through roll stress resultant analysis is evaluated. In order to decrease the roll stress, new pass schedule is developed for stable load balance between intermediate and finishing rolling stand. Therefore new rolling pass schedule is verified by the analysis results of rolling process and roll stress. By the analysis results, the credibility of rolling process analysis was obtained and it was determined that the possibility of roll damage between intermediate and finishing mill was high. So the new pass schedule was developed. Through the result of rolling process and roll stress analysis, it was obtained that the reduction of roll stress and stable load balance.

• 한국정밀공학회지
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• 제15권2호
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• pp.45-52
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• 1998

The contact roll is often used to regulate the winding tension as well as the entrained air in a wound roll by adjusting the contact force to the winding roll. But the contact force generated by other rolls, like assistant nip rolls, in a winding(or roll changing) process may act as disturbance to the control of the winding tension. In this paper, the mechanism of a roll change process is analysed. Ana, the behavior of the contact and the nip rolls are mathematically modeled. A nonlinear PID(NPID) controller is designed to control the winding tension and to reject the effect of disturbance generated by the nip roll on the winding tension variation. Computer simulation study showed that the performance of the suggested NPID controller is improved compared with that of the PID controller in controlling the winding tension and in rejecting the effect of the disturbance.

• Design & Manufacturing
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• 제17권3호
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• pp.15-20
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• 2023

In the fine blanking process, which is a press operation known for producing parts with narrow clearances and high precision through the application of high pressure, die roll often occurs during the shearing process when the punch penetrates the material. This die roll phenomenon can significantly reduce the functional surface of the parts, leading to decreased product performance, strength, and fatigue life. In this research, we conducted an in-depth analysis of the factors influencing die roll in the curvature area of the fine blanking process and identified its root causes. Subsequently, we designed and experimentally verified a die roll reduction process specifically tailored for the door latch manufacturing process. Our findings indicate that die roll tends to increase as the curvature radius decreases, primarily due to the heightened bending moment resulting from reduced shape width-length. Additionally, die roll is triggered by the absorption of initial punch energy by scrap material during the early shearing phase, resulting in lower speed compared to the product area. To mitigate the occurrence of die roll, we strategically selected the Shaving process and carefully determined the shaving direction and clearance area length. Our experiments demonstrated a promising trend of up to 75% reduction in die roll when applying the Shaving process in the opposite direction of pre-cutting, with the minimum die roll observed at a clearance area length of 0.2 mm. Furthermore, we successfully implemented this approach in the production of door latch products, confirming a significant reduction in die roll. This research contributes valuable insights and practical solutions for addressing die roll issues in fine blanking processes.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1999년도 제3회 압연심포지엄 논문집 압연기술의 미래개척 (Exploitation of Future Rolling Technologies)
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• pp.88-97
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• 1999

In this study, a systematic approach for roll pass design in bar rolling was studied. To minimize the trial and errors in the process design, a roll CAD system and a FE analysis system were combined. Based on the system, a methodology for roll pass design by FEM was studied. At first, designed process was compared with the FE analysis results and process redesign based on the FEM results was performed to obtain the specified final geometry. Then, empirical formula for roll speed set-up was compared with the FE analysis results. Further study on various simulations for bar rolling will help in making up for the inaccuracy in the currently used empirical roll speed rules. In addition, verification of the accuracy of the FE analysis system must be performed using experimental data in the industry.

• 대한기계학회논문집A
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• 제27권11호
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• pp.1881-1888
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• 2003

This study show a numerical method to predict roll wear in the roll forming process. Archard's wear model was reformulated in an elemental form to predict volume of roll wear and then wear depth on the roll was calculated using the results of finite element analysis. Abrasive wear occurs at contact area in the roll forming process and the results of simulation are compared with experimental data in production line. The wear simulation approach with 3-D FEM program for roll forming process, SHAPE-RF is in good agreement with it in tendency.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.748-753
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• 1996

The contact roll is often used to regulate the winding tension as well as the entrained air in a wound roli by adjusting the contact force to the winding roll. But the contact force generated by other rolls, like assistant nip rolls, in a winding(or roll changing) process may act as disturbance to the control of the winding tension. In this paper, the mechanism of a roll change process is analyzed. And, the behavior of the contact and the assistant nip rolls are mathematically modeled. A nonlinear PID(NPID) controller is designed to control the winding tension and to reject the effect of disturbance generated by the assistant nip roll on the winding tension variation. Computer simulation study showed that the performance of the suggested NPID controller is improved compared with that of the PID controller in con trolling the winding tension and in rejecting the effect of the disturbance.

• 한국정밀공학회지
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• 제10권3호
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• pp.69-80
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• 1993

It is important to prevent roll failure in hot rolling process for reducing maintenance coat and production loss. Roll material and rolling conditions such as the roll force and torque have been intensively investigated to overcome the roll failures. In this study, a computer roll life prediction system under working condition is developed and evaluated on IBM-PC level. The system is composed and fatigue estimation models which are stress analysis, crack propagation, wear and fatigue estimation. Roll damage can be predicted by calculating the stress anplification, crack depth propagation and fatigue level in the roll using this computer model. The developed system is applied to a work roll in actual hot rolling process for reliability evaluation. Roll failures can be diagnosed and the propriety of current working condition can be determined through roll life prediction simulation.