• Transactions of Materials Processing
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• v.23 no.6
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• pp.369-375
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• 2014

Flexible roll forming allows profiles to have variable cross-sections. However, the profile may have some shape errors, such as, warping which is a major defect. The shape error is induced by geometrical deviations in both the concave zone and the convex zone. In the current study, flexible roll forming was modeled with FE simulations to analyze the shape error and the longitudinal strain distribution along the flange section over the profile. A distribution of analytically calculated longitudinal strains was used to develop relationships between the shape error and the longitudinal strain distribution as a function of the defined shape parameters for the profile. The FE simulations showed that the shape error is primarily affected by the deviations between the distribution of analytically calculated longitudinal strain and the longitudinal strain distribution of the profile. The results show that the shape error can be controlled by designing the shape parameters to control the geometrical deviations at the flange section in the transition zones.

• Transactions of Materials Processing
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• v.22 no.7
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• pp.401-406
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• 2013

The use of roll-formed products increases every year due to its advantages, such as high production rates, reduced tooling cost and improved quality. However, till now, it is limited to part profiles with constant cross section. In recent years, the flexible roll forming process, which allows variable cross sections of profiles by adaptive roll stands, was developed. In this study, an attempt to optimize profile design for the flexible roll forming process was performed. An equation that predicts the longitudinal strain for part geometries with variable cross-sections was proposed. The relationship between geometrical parameters and the longitudinal strain was analyzed and investigations on the optimal profile design were performed. Experiments were conducted with a lab-scale roll forming machine to validate the proposed equation. The results show that the profile design method proposed in this study is feasible and parts with variable cross sections can be successfully fabricated with the flexible roll forming process.

• Korean Journal of Materials Research
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• v.33 no.2
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• pp.54-62
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• 2023

The most comprehensive and particularly reliable method for non-destructively measuring the residual stress of the surface layer of metals is the sin²ψ method. When X-rays were used the relationship of ε_φψ-sin²ψ measured on the surface layer of the processing metal did not show linearity when the sin²ψ method was used. In this case, since the effective penetration depth changes according to the changing direction of the incident X-ray, σ_φ becomes a sin²ψ function. Since σ_φ cannot be used as a constant, the relationship in ε_φψ-sin²ψ cannot be linear. Therefore, in this paper, the orthogonal function method according to Warren's diffraction theory and the basic profile of normal distribution were synthesized, and the X-ray diffraction profile was calculated and reviewed when there was a linear strain (stress) gradient on the surface. When there is a strain gradient, the X-ray diffraction profile becomes asymmetric, and as a result, the peak position, the position of half-maximum, and the centroid position show different values. The difference between the peak position and the centroid position appeared more clearly as the strain (stress) gradient became larger, and the basic profile width was smaller. The weighted average strain enables stress analysis when there is a strain (stress) gradient, based on the strain value corresponding to the centroid position of the diffracted X-rays. At the 1/5 I_max max height of X-ray diffraction, the position where the diffracted X-ray is divided into two by drawing a straight line parallel to the background, corresponds approximately to the centroid position.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.08a
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• pp.153-162
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• 2004

The force profile from strip to work roll is very important factor in deformation of roll. But It is not easy to predict the profile because strip crown affect its tendency. From finite element method result, some assumptions can be obtained and the roll force profile model is derived. Also the tension profile and lateral strain are derived. The prediction accuracy of the proposed model is examined through comparison with finite element calculation result.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.28 no.5A
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• pp.699-707
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• 2008

For most structural evaluation of bridge integrity, it is very important to measure the geometric profile, which is a major factor representing the global behavior of civil structures, especially bridges. In the past, because of the lack of appropriate methods to measure the deflection profile of bridges on site, the measurement of deflection has been restricted to just a few discrete points along the bridge, and the measuring points have been limited to the locations installed with displacement transducers. Thus, some methods for predicting the static deflection by using fiber optic strain sensors has been applied to simply supported bridges. In this study, a method of estimating the static deflection profile by using strains measured from suspension bridges was proposed. Based on the classical deflection theory of suspension bridges, an equation of deflection profile was derived and applied to obtain the actual deflection profile on Namhae suspension bridge. Field load tests were carried out to measure strains from FBG strain sensors attached inside the stiffening girder of the bridge. The predicted deflection profiles were compared with both precise surveying data and numerical analysis results. Thus, it is found that the equation of predicting the deflection profiles proposed in this study could be applicable to suspension bridges and the FBG strain sensors could be reliable on acquiring the strain data from bridges on site.

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.223-228
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• 2007

The profile ring rolling process of Ti-6Al-4V alloy was investigated by finite element(FE) simulation and experimental analysis. The process design of the profile ring rolling includes geometry design and optimization of process variables. The geometry design such as initial billet and blank sizes, and final rolled ring shape was carried out with the calculation method based on the uniform deformation concept between the wall thickness and ring height. FEM simulation was used to calculate the state variables such as strain, strain rate and temperature and to predict the formation of forming defects during ring rolling process. Finally, the mechanical properties of profiled Ti-6Al-4V alloy ring product were analyzed with the evolution of microstructures during the ring rolling process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.312-315
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• 2002

This paper summarizes the results of a numerical study conducted to analyze the effect of selected process parameters on material flow and thread profile in thread rolling of large diameter blanks. Based on the previous work where a plane strain mode was found to provide a reasonable approximation of the thread rolling process, the effect of varying thread form, friction factor, flow stress, and blank diameter on effective strain and thread height was analyzed using the finite element code DEFORM. This study show that effective strain for flank angle, that blank diameter had important effect on the as-rolled thread while flow stress, friction factor, and crest round of dies had significant impact on effective strain at the thread root and crest and load of thread rolling. While the rate of strain harding was found to have an effect on the crest profile, the results indicate that it is the primary factor responsible for seam formation in rolled threads.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.357-360
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• 2007

The profile ring rolling process of Ti-6Al-4V alloy was designed by finite element(FE) simulation and experimental analysis. The design includes geometry design and optimization of process variables. The geometry design such as initial billet and blank sizes, and final rolled ring shape was carried out with the calculation method based on the uniform deformation concept between the wall thickness and ring height. FEM simulation was used to calculate the state variables such as strain, strain rate and temperature and to predict the formation of forming defects during ring rolling process. Finally, the mechanical properties of profiled Ti-6Al-4V alloy ring product were analyzed with the evolution of microstructures during the ring rolling process.

• Steel and Composite Structures
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• v.7 no.1
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• pp.71-85
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• 2007

This study suggests modular composite profile beams, where the prefab concept is applied to existing composite profile beams. The prefab concept produces a beam of desired size having two types of profile: side module and bottom module. Module section will improve construction efforts because it offers several benefits : reduction of deflections due to creep and shrinkage, which might be found in existing composite profile beams; increase in span/depth ratio; and free prefabrication of any required beams. Based on the established analysis theory of composite profile beams, an analysis theory of modular composite profile beams was suggested, and analysis values were compared with experimental ones. The behavior of individual modules with increase of load was measured with a strain gauge, and the shear connection ratio between modules was analyzed by using the measured values. As a result of experiment, it was found that theoretical flexural strength on condition of full connection was 57%-80% by connection of modules for each specimen, and it is expected that flexural strength will approximate the theoretical levels through further module improvement.

• Transactions of Materials Processing
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• v.28 no.4
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• pp.190-196
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• 2019

The capability of accurately predicting the roll force profile across a strip in the bite zone in cold rolling process is vital for the calculation of strip profile. This paper presents a derivation of a precision mathematical model for predicting variations in the roll force across a strip in cold rolling. While the derivation is based on an approximate 3-D theory of rolling, this mathematical model also considers plastic deformation in the pre-deformation region which is located close to the roll entrance before the strip enters the bite zone. Finally, the mathematical model is expressed as a boundary value problem, and it predicts the roll force profile and tension profile in addition to lateral plastic strain profile.