• 한국정밀공학회지
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• 제34권3호
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• pp.199-203
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• 2017

Hot embossing techniques are used to engrave patterns on plastic substrates. Roll based hot embossing uses a heated roll for a continuous process. A heated roll with relief patterns is impressed on a preheated plastic substrate. Then, the substrate is cooled down quickly to prevent thermal shrinkage. The roll speed is normally very slow to ensure substrate temperature increase up to the glass transition temperature. In this paper, we propose a noncontact preheating technique using focused infrared light. The infrared light is focused as a line beam on a plastic substrate using an elliptical mirror just before entering the hot embossing roll. The mid range infrared light efficiently raises the substrate temperature. For preliminary tests, substrate deformation and temperature changes were monitored according to substrate speed. The experiments show that the proposed technique is a good possibility for high speed hot embossing.

• 열처리공학회지
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• 제31권2호
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• pp.63-67
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• 2018

Recent mold industry uses many roll-to-roll processes that can produce high production speed and precision machining and automation process. In the circular cylinder mold, however, patterns of less than $10{\mu}m$ are difficult to manufacture and maintain. In this study, we fabricated a circular cylindrical mold with a DLC thin film which have high hardness, low coefficient of friction and high releasability by using lithography and lift-off process. The height, line width, and pitch of the fabricated DLC macro pattern are $3.1{\mu}m$, $9.1{\mu}m$ and $20.2{\mu}m$, respectively. The pattern size is finer than the current applied to the aluminum cylinder type, and this shows the possibility of practical use of DLC micro pattern roll mold.

• 한국기계가공학회지
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• 제16권4호
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• pp.38-45
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• 2017

A finite element analysis-based approach which investigates the causes of the breakdown in the outer ring of the choke at hot rod rolling mill is presented. Two-dimensional drawings of the whole vertical-type mill stand are transformed into three-dimensional CAD models. Non-linear elasto-plastic deformation analysis of material at the roll gap is performed for computing roll force and torque of the work roll. Then, the reaction forces of the bearing rings together with a set of roller bearings that support the work roll are obtained by means of rigid body motion analysis. Finally, stress behaviors in the bearing rings together with a set of roller bearings that support the work roll are investigated by linear elastic analysis. Results reveal that stress at the contact area between the outer ring and roller bearing is extraordinary high when an internal gap between an external surface of the outer ring and the internal surface of the chock due to wear of the inside of the chock occurs.

• 한국해양공학회지
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• 제13권4호통권35호
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• pp.75-81
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• 1999

Roll forming process is simulated with a commercial FEM code LS-DYNA. The rolls are treated as rigid bodies rotating with a constant angular velocity. The strip and the rolls are modeled with 4-node plate elements. It is assumed that the nodes along the front end of the strip move along paths given by sine functions. It is found that the analysis can be applied to the optimal design of forming rolls. With these analyses, it is expected that forming defects can be avoided and process development efforts can be reduced.

• 한국정밀공학회지
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• 제26권12호
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• pp.94-101
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• 2009

In diesel engines, it is inevitable that the torsional vibration is produced by the fluctuation of engine torque. Therefore, it is necessary to establish preventive measures to diminish the torsional vibration. The sleeve spring type damper is one of the preventive measures for reducing the torsional vibration. In this study, 2-roll bending process was proposed to manufacture sleeve spring; The program to calculate the initial radius including springback effect was developed and the FEA method to analyze elasto-plastic problem was verified through analysis of 90 degree bending process. The elasto-plastic analysis of 2-roll bending process was carried out by the FEA method verified to set a new criterion, and the new process design parameter(contact angle) in the 2-roll bending process was proposed.

• 한국정밀공학회지
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• 제15권8호
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• pp.145-155
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• 1998

An $H{\infty}$ controller with a roll eccentricity filter is proposed to alleviate the effect of entry thickness variation and roll eccentricity occured in rolling stands themselves of tandem cold mills. A robust controller to the disturbances is designed by H$_{\infty}$ control techniques, which can reflect the input direction of disturbances and the knowledge of disturbance spectrum in the frequency domain. First, fundamental problems in tandem cold mills such as process transport delay inherent in the exit thickness measurement and the feedforward loading of roll eccentricity signals on the exit thickness be overcome by the roll eccentricity filtering and the compensation for the error of gaugemeter thickness estimator. And non-satndard $H{\infty}$ control problem caused by the selection of weighting function having poles on the $J{\omega}$-axis is discussed. The resultant controller composed by an $H{\infty}$ controller and an estimator for the roll eccentricity is evaluated through computer simulations. The effectiveness of the proposed control method is compared to that of the conventional LQ controller method and a feedforward controller for the roll eccentricity, which has been already studied.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2001년도 ICCAS
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• pp.121.4-121
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• 2001

We propose an off-line methodology for detecting a faulty backup roll that generates eccentricity components, under the condition that the feeding velocity, equivalently the angular velocity of roll, is not constant. From a newly devised speed angle conversion algorithm, we transform all process data into those of a virtual process under a constant feeding speed. This indirectly way, we can apply a spectral analysis to the original process. In addition, we develop an online detection method of roll eccentricity based on newly designed PLG sensor. This PLG sensor is robust because of applying magnetic proximity sensnors and non-contact measurement method.

• 소성∙가공
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• 제21권1호
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• pp.19-23
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• 2012

In this paper, a Mannesmann roll piercing process equipped with Diecher's guiding discs is investigated using a rigid-thermoviscoplastic finite elements method with intelligent remeshing capability and tetrahedral elements. The analysis model is presented and the approach is applied to a Mannesmann roll piercing process found in the literature. Details about the remeshing criterion as well as mesh density control are given. The present predictions are compared with the predictions found in the literature, showing that the two predictions are in close agreement in terms of the deformed shape. However, it is emphasized that the present approach has the distinct strength in predicting details of final shape.

• Fibers and Polymers
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• 제7권4호
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• pp.424-431
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• 2006

Roll drafting, a mechanical operation attenuating fiber bundles to an appropriate thickness, is an important operation unit for manufacturing staple yams. It influences not only the linear density regularity of the slivers or staple yams that are produced, but also the quality of the textile product and the efficiency of the thereafter processes. In this research, the dynamic states of the fiber bundle in the roll drafting zone were analyzed by simulation, based on the mathematical model that describes the dynamic behavior of the flowing bundle. The state variables are the linear density and velocity of the fiber bundles and we simulated the dynamics states of the bundle flow, e.g., the profiles of the linear density and velocity in the draft zone for various values of the model parameters and boundary conditions, including the initial conditions to obtain their influence on the dynamic state. Results showed that the mean velocity profile of the fiber bundle was strongly influenced by draft ratio and process speed, while the input sliver linear density has hardly affected the process dynamics. Velocity variance of individual fibers that could be supposed to be a disturbing factor in drafting was also influenced by the process speed. But the major disturbance occurred due to the velocity slope discontinuity at the front roll, which was strongly influenced by the process speed. Thickness of input sliver didn't play any important role in the process dynamics.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2008년도 추계학술대회A
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• pp.1255-1258
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• 2008

Roll to roll (R2R) system, known as 'web processing', is the process of producing these electronic devices on a roll of flexible plastic. With the need of improved performance and productivity in R2R industry, effective control and on-line supervision for web quality is essential. In this report, we present a system for on-line measurement of wrinkles, one of defects incurring due to compressive stresses developed in the web. This system is able to capture an image generated when a well defined line shape laser beam passes through a transparent web. The system calculates 3D shape information, including the height of the wrinkle on the web, and displays the images for the shape information of the web in real time. By using area scan camera and machine vision laser, this system takes more advantages of setting up as a simple and low cost system compared to the line scan camera systems that widely used in web manufacturing. Specific calibration method and analysis on the achievable accuracy will be discussed.