• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.413-416
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• 2007

In general, by means of the electrodepositing technique, a copper foil sample was prepared with a high purity and a high density. But the mechanical properties of the electrodepositing copper foil was lower than it's the rolling copper foil. However, the production of copper foil with approximately 36 microns thick in rolling process was very difficult. This paper describes the outline of the high accuracy cold rolling in 6 high mill which was developed for the purpose of rolling very thin accurate gauge copper foil(36 micron thick), and give several rolling characteristic of 600 mm wide copper foil. a) Large strain can be accumulated pass by pass in industrial multi-pass rolling processing to overcome large critical strain for thickness accuracy through optimization of rolling schedule. b) Also, permissible tension for rolling 0.45 $\sim$ 0.036 mm thick copper strip stably in accordance with the each pass work had been established by FEM simulation results. c) During the plate rolling process, considerable values of the forces of material pressure on the tool occur. These pressures cause the elastic deformation of the roll, thus changing the shape of the deformation region. A numerical simulation of roll deflection during cold rolling is presented in the paper. d) The proposed pass schedule can roll very thin copper foil of 36 micron thickness to a tolerance of ${\pm}1$ microns. The validity of simulated results was verified into rolling experiments on the copper foil.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2008.06a
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• pp.813-814
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• 2008

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.184-187
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• 2003

The simulation program is developed to get the target strip crown of high strength steel in the continuous hot strip rolling. The developed program consists of several sub-program, which contains work roll shifting pattern, roll wear profile, roll thermal expanded profile and strip profile. Also, the variation of strip profile is investigated according to roll deflection and flattening. The results are compared with the values observed from the actual hot rolling of high strength steel. And effect of bender force on the strip profile is studied. The strip crown is shown to decrease with increasing bender force.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.58-65
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• 1997

Work rolls used in cold rolling mills must have outstanding wear resistance and very little plastic defor- mation. Thus, these rolls require a higher surface hardness and harding to a greater depth. To meet these requirements, the rolls, in general, have basic chemical composition of 0.7 to 1.0% carbon and 1.0 to 5.0% Cr(chromium), plus a small amounts of special elements, and are subjected to intensive water quenching and tempering at low temperature to provide a surface hardness of over 90 shore. This test results are as follows. Deflection and fracture load of 5% Cr material are than those of 3% Cr material and show flat curve from surface to subsurface. It will be clear that 5% Cr work roll has a superior resisti- bility against wear and abrasion comparing with 3% Cr work roll. The improvement of wear and abrasion in 5% Cr work roll will be achieved by the large amount of wpheroidal carbide. In grindability and polish, 5% Cr work roll will be a little inferior comparing with 3% Cr work roll.

• Design & Manufacturing
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• v.18 no.2
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• pp.1-8
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• 2024

Unlike the roll-to-roll process that uses a steel roll and a nip roll, a vacuum roll can hold and transfer a thin film using a single roll. To precisely manufacture a vacuum roll, a thin outer cylinder must be machined, which is assembled on the outside of the roll and contacts the film via vacuum pressure. In this study, the effects of jaw width and chucking force on the deformation of the outer cylinder during the turning process were investigated using analysis, and a precision machining and burr removal process was developed. The deformation of the outer cylinder decreased almost linearly with increasing jaw width and increased with higher chucking force and larger cylinder diameter. Additionally, the deflection due to the weight of the outer cylinder was approximately three times greater than that caused by film tension. For the machined outer cylinder, a burr removal experiment was conducted, and concentricity and cylindricity were measured. Using a device that removes burrs by rotating a wheel connected to the main shaft at high speed, it was found that burrs generated on the inner diameter could be removed very efficiently. On the vacuum side, the concentricity errors of the inner and outer diameters were 0.015 mm and 0.014 mm, respectively, and on the opposite side, they were 0.006 mm and 0.010 mm, respectively. Additionally, the measurement of Total Indicator Runout (TIR) according to the angle showed that the maximum cylindricity of the outer and inner diameters was 0.02 mm and 0.025 mm, respectively. Finally, through burr-height measurement at the hole boundary, it was found that the heights were within 0.05 mm.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.4
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• pp.723-730
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• 1998

With the introduction of edge drop control system in Tandem Cold Rolling Mill, it is necessary to develop te numerical expression for the set-up and edge drop automatic control of cold rolled sheet. As a first step we developed a simulation program which predicts profile and the amounts of edge drop at the delivery side of each stand by using roll deformation anlysis with the slit roll model. And by using the program the effect of various rolling conditions on edge drop was investigated. As a result the relations were obtained between the amounts of edge drop and rolling conditions. Based on above relations, the numerical expression was developed for the set-up and automatic control of edge drop by multi-regression of simulation results for the variation of edge drop amount with each rolling condition.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.12
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• pp.209-216
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• 2000

The lateral behavior of the moving web is critical to the quality of the web products. The alignment of the rollers carrying the web is found to be one of important factors to the lateral behavior of the moving web. But, the study on the effect of the tilting roller in the direction of the normal to the moving web on the lateral behavior has not been reported in the literature yet. For example, the contact roller often contacts the winding roll in a tilted fashion and causes the lateral motion of the winding web, which induces the offset on the wound roll. The lateral dynamics of the moving web induced by a tilted roller in normal direction of a web is investigated in this paper. The two-dimensional dynamic model developed by Shelton is extended to investigate the effect of a titled roller in a normal direction of the moving web on the lateral motion of the moving web. New boundary conditions are developed to solve the extended model. Computer simulation study proved that the model developed can be used to predict the lateral motion of the moving web ？ to a tilted roller in normal direction of the moving web. The lateral deflection is increased exponentially a the tilting angle is increased. As the length of web span is increased, the amount of lateral deflection was increased almost linearly for the same tilting angle. The lateral dynamics turned out to be almost independent to the operating tension. The model developed can be used to solve the offset problem of the staggered winding and also to design a new web guiding mechanism.

• Journal of Mechanical Science and Technology
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• v.17 no.3
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• pp.321-328
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• 2003

The elongation of contact length on the line of action is considered with particular reference for roll forming of gears, and for dynamic behavior of the tooth in meshing. However there is no paper that discuss the elongation of contact length in the load meshing of gears. Based on our investigation, the contact length on the line of action elongates more than the kinematically calculated value. In rolling, as the tool approaches the workpiece, the center distance of the gears decreases by a small amount. But, the elongation of contact length is sensitive. Therefore, the contact point on the line of action is difficult to be determined, which complicates the tooth analysis. In this study, the exact relation between the elongation of contact length and the tooth space over the recess or before the approach are revealed by experiments and kinematic theory. This analytical result applies not only for rolling, but also for the single flank meshing which is done under constant center distance.

• Journal of Industrial Technology
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• v.19
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• pp.31-42
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• 1999

This paper presents a method for evaluating the performance of a leaf spring suspension and an air spring suspension systems for trucks in terms of ride and handling. Leaf springs, which generally have non-linear progressive force-deflection characteristics, are modeled using beam and contact elements. The leaf spring analysis model shows good correlation with experimental results. Each component of an air spring suspension system, which is a single leaf, air spring, height control valve, compressor and linkages, is modeled appropriately. Non-linear characteristics of air spring are accounted for using the measured data, and pressure and volume relations for height control system is also considered. The wheel rate of the air suspension is taken lower but roll stiffness is taken higher than those of leaf springs to improve ride and handling performance, which is verified through driving simulations.

• International Journal of Control, Automation, and Systems
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• v.4 no.2
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• pp.255-270
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• 2006

In this paper, a design method of nonlinear autopilot for ship-to-ship missiles is proposed. Ship-to-ship missiles have strongly coupled dynamics through roll, yaw, and pitch channel in comparison with general STT type missiles. Thus it becomes difficult to employ previous control design method directly since we should find three different solutions for each control fin deflection and should verify the stability for more complicated dynamics. In this study, we first propose a control loop structure for roll, yaw, and pitch autopilot which can determine the required angles of all three control fins. For yaw and pitch autopilot design, missile model is reduced to a minimum phase model by applying a singular perturbation like technique to the yaw and pitch dynamics. Based on this model, a multi-input multi-output (MIMO) nonlinear autopilot is designed. And the stability is analyzed considering roll influences on dynamic couplings of yaw and pitch channel as well as the aerodynamic couplings. Some additional issues on the autopilot implementation for these coupled missile dynamics are discussed. Lastly, 6-DOF (degree of freedom) numerical simulation results are presented to verify the proposed method.