• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.25-28
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• 2002

This paper is concerned with the design of roller profiles in tube/pipe straightener with both methods of Computer Aided Design and Computer Aided Engineering. Design analysis is carried out from two point of view. The one is the research in the minimization of tube pitch which was very important factor in levelling process. In order to minimize tube pitch, profiles of the roller were calculated so that the contact region between roller and tube was maximized. The other is determination of an optimum amount of intermesh for the proper progress without a jam in levelling process. Generally the jamming trouble was casued by excessive amount of intermesh in levelling process. The optimum amount of intermesh was determined through the finite element analysis.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.271-274
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• 2009

This paper deals with an evaluation of the product quality according to intermesh of the roller straightening process of a steel cord. To perform the experiments, a single-layered steel cord with three wires is selected as a target. Intermeshes at inlet and outlet of the roller straightening device are selected as a respective design parameter. According to two intermeshes of the roller straightening device, a design table is generated and experiments were performed. Three assessment items of the product quality, such as the residual torsion, the arc-height and the pre-forming ratio, are measured in each experimental case for the quantitative evaluation of a steel cord. Based on the measured data, the sensitivity of two intermeshes was analyzed and the prediction equation for the product quality of a steel cord was also constructed from the regression analysis.

• Transactions of Materials Processing
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• v.11 no.2
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• pp.147-154
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• 2002

The tension levelling Process is Performed to elongate the strip plastically In combination of tensile and bending strain so that all longitudinal fibers In the strip have an approximately equal amount ofn length and undesirable strip shapes are corrected to the flat shape. Thus paper is concerned with a simulation of the tension levelling process based on the analysis of tile unit model for the tension leveller. Analysis technique such as the sequential analysis of the unit model is suggested and verified with the assembly analysis of the unit model for the effective arts economic analysis of the full set of the tension leveller. Analysis of the full tension levelling Process using sequential unit models Is carried out for steel strips with the shape defect and provides the effect of the intermesh and optimum amount of the intermesh in tension levelling process.

• Transactions of Materials Processing
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• v.22 no.1
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• pp.11-16
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• 2013

Despite its importance the control of roller leveling has primarily relied on the operator's experience and on operation tables. In order to effectively eliminate various shape defects, the optimal leveling condition for a specific mode of plate deformation needs to be determined as well as a careful evaluation as to whether or not the condition is still appropriate for other modes or not. A numerical model, which considers both computation efficiency and accuracy, has been developed. The variations of residual stress are studied according to the entry and the delivery intermeshes, respectively. The camber deformation decreases linearly as the entry intermesh increases. In contrast the curl deformation does not vary directly with the entry intermesh. Therefore, the optimum intermesh values need to be determined in order to simultaneously minimize both the camber and the curl deformation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.201-204
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• 2001

The tension levelling process is performed to elongate the strip plastically in combination of tensile and bending strain so that all longitudinal fibers in the strip have an approximately equal amount of length and undesirable strip shapes are corrected to the flat shape. This paper is concerned with a simulation of the tension levelling process based on the analysis of the unit model for the tension leveller. Analysis technique such as the sequential analysis of the nit model is suggested and verified with the assembly analysis of the unit model for the effective and economic analysis of the full set of the tension leveller. Analysis of the full tension levelling process using sequential unit models is carried out and provides the effect of the intermesh and optimum amount of the intermesh in tension levelling process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.233-235
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• 2007

Finite element analysis was conducted for cold roller leveler to verify numerical model of roller leveler developed by POSTECH. On-line model of roller leveler was developed to predict rapid and precise roll intermesh of roller leveler in thick plate mill. The cold roller leveler in thick plate mill was analyzed using MARC & MENTAT and the results are compared with the results of numerical model of roller leveler calculated by POSTECH.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.42-48
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• 2000

This paper is concerned with a simulation-based process design for the tension levelling of metallic strips based on the elasto-plastic finite element analysis with reduced integration and hourglass control. The tension levelling process is performed to elongate the strip plastically in combination of tensile and bending strain by a controlled manner so that all longitudinal fibers in the strip have an approximately equal amount of length and undesirable strip shapes are corrected to the flat shape. The analysis deals with a method for calculating the quantitative level of the curl to investigate the roll arrangements and intermesh suitable to elimination of the curl. The analysis provides the information about the intermesh effect on the amount, the tension effect and distribution of the strain as well as the stress in order to determine the amount of elongation for correction of the irregular shape. The desired elongation is referred to determine the number of work rolls and the value of tension. Especially, the analysis investigates tile effect of the mesh size in the non-steady state finite element analysis on the amount and distribution of the strain.

• Transactions of Materials Processing
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• v.11 no.2
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• pp.138-146
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• 2002

This paper is concerned with the simulation-based process design method involved non-steady state problem of tension levelling considering the elasto-plastic hardening behavior of a metallic strip by a commercial code ABAQUS/Standard. The tension levelling process is peformed to elongate the strip plastically in combination of tensile and bending strain by a controlled manner so that all longitudinal fibers in the strip have an approximately equal amount of length and undesirable strip shapes are corrected to the flat share. Objectives of this paper are the development of a general method for the design of a tension leveller by a finite element method and parameter studies for the deisgn variables such as the applied tension, the roll intermash includes the determination of the steady state using the simple unit of the tension levelling line and the effect of the finite element mesh size on the amount and distribution of the strain calculated. The analysis provides the information about the intermesh effect on the amount and final shapes of the strip and distribution of the strain in order to determine the amount elongation for correction of the irregular share.

• Transactions of Materials Processing
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• v.13 no.6 s.70
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• pp.497-502
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• 2004

The shape of cold rolled steel sheets is defined as the degree of flatness, and the flatter, the better. Because undesirable strip shapes of cold rolled steel sheets can affect not only visible problem but also automatic working process in customer's lines, the requirement of the customers is more and more stringent. So we usually used the tension leveler to make high quality of strip flatness. For the improvement of the quality of strip flatness, this report developed three- dimensional FEM (Finite Element Method) simulation model, and analysis about the strain and stress distribution of strip in the tension leveling process. The numerical study can be summarized as follows. (1) If we pass the edge wave material (steepness: $1.0\%$) that the stress-difference between the strip center and the edge is 5.2kgf through tension leveler. the stress-difference is decreased 0.45kgf and the steepness is improved to $0.29\%$. (2) If the Intermesh is increased from 6mm to 7mm, the steepness is improved from $0.294\%$ to $0.268\%$. (3) If the initial steepness is decreased form $1.0\%$ to $0.75\%$, the final steepness is improved from $0.294\%$ to $0.263\%$. We know that more increased intermesh and lower initial steepness make the final steepness improved.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.245-248
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• 2008

This paper deals with the parameter study of roller leveling process of steel cord using finite element analysis. A simplified model of roller leveling process is constructed for the efficient numerical simulation considering the computing time. Using the constructed simulation scheme, the parameter study of main process parameters, such as back-tension and intermesh, is carried out in order to evaluate elastic recovery angle and roller force quantitatively. The effect of the initial shape of steel cord is also evaluated during the parameter study. And the mechanism of roller leveling process is verified by investigating the residual stress distribution.