• 제어로봇시스템학회:학술대회논문집
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• 2000.10a
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• pp.38-38
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• 2000

To fulfill recent requirements for high quality products in steel rolling process, fast responding and easily tunab control system is required and ILQ(Inverse Linear Quadratic) control system may be one of such alternatives. In this paper characteristics of ILQ control and its application to BUR(Back-Up-Roll) eccentricity in strip rolling mill is discussed and compared to polynomial control approaches. Also the rolling mill model and basic principle to control thickness of srip are introduced with control effect by polynomial methods.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.319-322
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• 2003

For the analysis of leveling process by the 3-dimensional elastic-plastic finite element method, a finite element analysis program modeling large deformation of shell has been developed. This program fur analyzing large deformation of sheet during leveling includes spring-back analysis as well as efficient contact treatment between sheet and rolls of leveler. This is verified by the simple leveling experiment with 5 rolls at laboratory. Besides the leveling examples, problems within the category of large strain and rotation, such as 3-dimensional roll-up and gutter occurrence at continuous bending-unbending process are also tested for verification of the program. The residual curvatures of strip predicted by finite element analysis are within 20% error range of the experiment. The formation and direction of anticlastic curvature or gutter during bending-unbending under tension is predicted and this agrees with the experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.199-202
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• 2009

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. Tn this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal Front Bumper Beam manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.144-147
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• 1998

VCR is a back-up roll with a special contour which leads to the length of the contact line between back-up roll and work becones self adjustable in accordance with the width of the strip. The simulation of a finite element model and the on-line test at production mill demonstrate that the VCR roll may keep the crown of the roll gap relatively stable, and at same time, permit the rolling pressure to be adjusted over a wider range, and increase the effect of work roll bending on the roll gap. The VCR rolls have been successfully used at the first stands of two largest cold rolling mills in China, and on-line test has been done at a wide hot strip finishing train. The use of VCR roll has created favorable conditions for subsequent rolling passes and the achievement of better flatness quality.

• Transactions of Materials Processing
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• v.24 no.3
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• pp.212-217
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• 2015

SmartCrown is a system to control the plate crown by shifting the sine-shaped work rolls in the axial direction. The control range of the plate crown depends on a depth of sine-shaped roll profile because the roll radius varies continuously along the axial direction. When the roll profile is changed to improve the control range, the contact stress between the work roll and the back-up roll also changes. In the current study, the contact stress for various profiles and rolling conditions were analyzed using the finite element method and compared with results from Hertzian contact theory. A submodel method is used to increase the accuracy of the finite element analysis. The analysis results showed that the maximum increase in the contact stress was only 53MPa, so it is anticipated that no back-up roll spalling will occur.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.357-360
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• 2008

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. In this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal SILL SIDE manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.310-313
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• 2007

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. In this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal roll flower model and proper roll-pass sequence can be suggested by analyzing courcenter strain and longitudinal strain according to the roll-pass with FEM simulation. And also effects of the process parameters on the final shape formed by roll forming defects a evaluated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1992.04a
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• pp.306-312
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• 1992

The prevention of roll breakage in hot rolling process is improtant to reduce maintenance cost and production loss. Rolling conditions such as the roll force and torque have been intensively studied to overcome the roll breakage. in the present work, a model for life prediction of work rolls under working condition was developed and discussed. The model consists of stress analysis, crack propagation, wear and fatigue calculation model. Roll life can be predicted by stress, crack depth and fatigue damage calculated from this model. The reliability of stress analysis is backed up by the FEM analysis. From the result of simulation using by pressent model, although the fatigue damage of back up roll reachs 80% of practical limit, that of workroll was less than 40%. In edge section of workroll stress amplification is found by wear and bender effect. We can judge that workroll failures are not due to fatigue damage, crack propagation by bending stress but stress amplification by wear and bender in present working condition.

• Transactions of Materials Processing
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• v.15 no.4 s.85
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• pp.311-318
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• 2006

One of the most important quality problems in flat plate leveled from hot rolled coils in cut-to-Iength lines is bowing and cambering when they are cut in small width parts. It is verified analytically and experimentally that residual stress remained in plate is th ε source of the problem. In order to produce low residual stress flat plate from hot rolled coils, the proper conditions of leveling are studied and two things are implemented. One is proper plastic deformation area ratio to reduce residual stress within customer requirement by applying suitable plastic deformation and maintain leveling load within structural strength limit of leveler. The other is maintaining uniform plastic deformation along the width of the plate during leveling. Customer requirement for residual stress is met by applying above 70% of plastic deformation area ratio and uniform deformation along width of coil by adjusting back up rolls according to deformation analysis of work roll and back up roll assembly and leveling tests.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.8
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• pp.96-103
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• 2009

The roll forming process is commonly used for the conventional 'Fe' metal products such as a furniture drawer guide or an up-down slide guide. Recently its applications are variously expanded to the sanitary facilities or electronic devices. It is essentially required the cleanness for the high technology application and any corrosion or rust are not allowed. Therefore, in those applications the stainless steel materials are strongly demanded as the substitution of 'Fe' steel. However the mechanical properties of stainless steel are not suitable for forming process compared with those of 'Fe' steel. Up to now, the conventional F.E.M.(Finite Element Method) has been used to analyze and design the roll forming process. The purpose of this research is to obtain the proper production process and the shape of rolls to manufacture the high precision slide rails made of stainless steel material. The commercial program, SHARPE-RF, is used to analyze the entire roll forming process. The results show that the rolling process and the roll design by F.E.M. are useful from the good agreement between the shapes of products estimated by F.E.M. and those of the actual products.