• Transactions of Materials Processing
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• v.11 no.8
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• pp.710-715
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• 2002

This paper describes the numerical determination of optimum blank diameter for sound material flow and high precise thread profile of a spindle screw through external thread rolling using two-three roll dies. Initial blank diameter affects the dimensional accuracy and surface finish qualities of a spindle screw in thread rolling process, therefore it is very important to determine the optimum blank diameter in thread rolling process. In order to determine the optimum blank diameter, this paper suggests the calculation method of initial bland diameter considering the real shape of tooth. The finite element code DEFORM is applied to analyze the metal flow of tooth, and these analytical results are verified by thread rolling experiment for spindle screw.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2007.11a
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• pp.217-218
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• 2007

• Elastomers and Composites
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• v.44 no.4
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• pp.391-396
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• 2009

This paper presents the numerical analysis of thread rolling. Firstly, the analysis is focused on the effective analysis conditions that guarantee the reliability of the analysis results. The investigated parameters are the number of teeth and the number of elements. Using the analysis results, the number of elements and the number of teeth that guarantee the results are found. And then, the effects of the process parameters such as tool shape and temperature on the thread rolling are investigated. The analysis is carried out using DEFORM-3D. The results show that the flank angle and crest round have an effect on the thread rolling load. It is also shown that temperature have significant effects on the effective strain distribution, rolling load, and crack initiation. The crack initiation is predicted using the Cockcroft-Latham criterion.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.5 s.176
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• pp.1215-1230
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• 2000

Parallel Approaches using Cray T3E which is NIPP (Massively Parallel Processors) machine are presented for the efficient computation of the finite element analysis of 3-D shape rolling processes. D omain decomposition method coupled with parallel linear equation solver is used. Domain decomposition is applied for obtaining element tangent stifffiess matrices and residual vectors. Direct and iterative parallel algorithms are used for solving the linear equations. Direct algorithm is_parallel version of direct banded matrix solver. For iterative algorithms, the well-known preconditioned conjugate gradient solver with Jacobi preconditioner is also employed. Moreover a new effective iterative scheme with block inverse matrix preconditioner, which is named by present authors, is presented and its results are compared with the one using Jacobi preconditioner. PVM and MPI are used for message passing and synchronization between processors. The performance and efficiency of each algorithm is discussed and comparisons are made among different algorithms.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.1
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• pp.56-62
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• 2003

The objective of this study is to adjust the roll gap for the dimension accuracy of bar in hot bar rolling process considering roll wear. In this study hot bar rolling processes for round and oval passes have been investigated. In order to predict the roll wear, the wear model is reformulated as an incremental form and then wear depth of roll is calculated at each deformation step on contact area using the results of finite element analysis, such as relative sliding velocity and normal pressure at contact area. Archard's wear model was applied to predict the roll wear. To know the effects of thermal softening of DCI (Ductile Cast Iron) roll material according to operating conditions, high temperature micro hardness test is executed and a new wear model has been proposed by considering the thermal softening of DCI roll expressed in terms of the main tempering curve. The new technique developed in this study for adjusting roll gap can give more systematically and economically feasible means to improve the dimension accuracy of bar with full usefulness and generality.

• Transactions of Materials Processing
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• v.32 no.3
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• pp.114-121
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• 2023

During rolling, rolling mill rolls endure wear when shaping metal billets into a desired form, such as bars, plates, and shapes. Such wear affects the lifespan of the rolls and product quality. Therefore, in addition to rigidity, wear performance is a key factor influencing the performance of rolling mill rolls. Conventional methods such as casting and forging have been used to manufacture rolling mill rolls. However, powder alloying methods are increasingly being adopted to enhance wear resistance. These powder manufacturing methods include atomization, canning to shape the powder, hot isostatic pressing to combine the powder alloy with conventional metals, and various wear performance tests on rolls prepared with powder alloys. In this study, numerical simulations and experimental tests were used to develop and elucidate the wear analysis mechanism of rolling mill rolls. The wear characteristics of the rolls under various rolling conditions were analyzed. In addition, experimental tests (wear and surface analysis tests) and wear theory (Archard wear model) were used to evaluate wear. These tests were performed on two different materials in various powder states to evaluate the different aspects of wear resistance. In particular, this study identifies the factors influencing the wear behavior of rolling mill rolls and proposes an analytical approach based on the actual production of products. The developed wear analysis mechanism can serve the future development of rolls with high wear resistance using new materials. Moreover, it can be applied in the mechanical and wear performance testing of new products.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.619-626
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• 2008

In this study, design methodology to determine optimal shape of the anvil in sizing press process has been proposed to minimize crop length of the AISI 1010 slab in horizontal rolling after width reduction. Shape of anvil were selected to 12 cases by design of experiment, and the dog-bone shapes and the crop length were determined by FE-analysis. Also, the anvil shape, which has minimum crop length, were determined by artificial neural network(ANN). As a result of FE-analysis, it can be seen that the crop length was increased with increasing center thickness in the dog-bone shape after width reduction. The anvil shape which has minimum crop length, was estimated to ${\theta}_{1}=21^{\circ}{\theta}_{2}=14^{\circ}$ by FE-analysis and ANN.

• Journal of Mechanical Science and Technology
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• v.18 no.6
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• pp.972-978
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• 2004

Forward slip is an important parameter often used in rolling-speed control models for tandem hot strip rolling mills. In a hot strip mill, on-line measurement of strip speed is inherently very difficult. Therefore, for the set-up of the finishing mill, a forward slip model is used to calculate the strip speed from roll circumferential velocity at each mill stand. Due to its complexity, most previous researches have used semi-empirical methods in determining values for the forward slip. Although these investigations may be useful in process design and control, they do not have a theoretical basis. In the present study, a better forward slip model has been developed, which provides for a better set-up and more precise control of the mill. Factors such as neutral point, friction coefficient, width spread, shape of deformation zone in the roll bite are incorporated into the model. Implementation of the new forward slip model for the control of a 7-stand hot strip tandem rolling mill shows significant improvement in roll speed set-up accuracy.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.333-336
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• 2008

The groove rolling is a process that transforms the bloom or billet into a shape with circular section through a series of rolling. Inhibition of surface defect generation in groove rolling is a matter of great importance and therefore many research groups proposed a lot of models to find the location of surface defect initiation. In this study, we propose a model for maximum shear stress ratio over equivalent strain to catch the location of surface defect onset. This model is coupled with element removing method and applied to box groove rolling of POSCO No. 3 Rod Mill. Results show that proposed model in this study can find the location of surface defect initiation during groove rolling when finite element analysis results is compared with experiments. The proposed criterion has been applied successfully to design roll grooves which inhibits the generation of surface defect.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.607-612
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• 2008

The groove rolling is a process that transforms the bloom or billet into a shape with circular section through a series of rolling. Inhibition of surface defect generation in groove rolling is a matter of great importance and therefore many research groups proposed a lot of models to find the location of surface defect initiation. In this study, we propose a model for maximum shear stress ratio over equivalent strain to catch the location of surface defect onset. This model is coupled with element removing method and applied to box groove rolling of POSCO No.3 Rod Mill. Results show that proposed model in this study can find the location of surface defect initiation during groove rolling when finite element analysis results is compared with experiments. The proposed criterion has been applied successfully to design roll grooves which inhibit the generation of surface defect.