A model based on the curvature integration method has been applied in an online plate leveling system. However, there are some shortcomings in the current leveling models. On the one hand, the models cannot deal with the leveling process of plates with a random curvature distribution. On the other hand, the current models are suitable only for stable leveling processes and ignore the biting in and tailing out stages. This study presents a new plate-leveling model based on the curvature integration method, which can describe the leveling process of plates with random curvature distribution. Further, the model is solved in two cases in order to take the biting in and tailing out stages into consideration. The proposed model is evaluated by comparing with a plate leveling experiment. Finally, the leveling process of a plate with a wave bent is studied using the proposed model. It is found that the contact angles vary greatly during the biting in and tailing out stages. However, they are relatively steady during the 5 roller leveling stage. In addition, the contact angle of roller No. 2 is the smallest, which is close to 0. Roller leveling can effectively eliminate bending in the plate, but there are regions in the head and tail of the plate, where roller leveling is not effective. The non-leveling region length is about 2 times that of the roller space. This study proposes a quasi-static plate-leveling model, which makes it possible to analyze the dynamic straightening process using a curvature integration method. It also makes it possible to analyze the straightening process of a plate with random curvature distribution.
Ben Guan
,
Chao Zhang
,
Yong Zang
,
Yuan Wang
. Model for the Whole Roller Leveling Process of Plates with Random Curvature Distribution Based on the Curvature Integration Method[J]. Chinese Journal of Mechanical Engineering, 2019
, 32(3)
: 47
-47
.
DOI: 10.1186/s10033-019-0361-7
A model based on the curvature integration method has been applied in an online plate leveling system. However, there are some shortcomings in the current leveling models. On the one hand, the models cannot deal with the leveling process of plates with a random curvature distribution. On the other hand, the current models are suitable only for stable leveling processes and ignore the biting in and tailing out stages. This study presents a new plate-leveling model based on the curvature integration method, which can describe the leveling process of plates with random curvature distribution. Further, the model is solved in two cases in order to take the biting in and tailing out stages into consideration. The proposed model is evaluated by comparing with a plate leveling experiment. Finally, the leveling process of a plate with a wave bent is studied using the proposed model. It is found that the contact angles vary greatly during the biting in and tailing out stages. However, they are relatively steady during the 5 roller leveling stage. In addition, the contact angle of roller No. 2 is the smallest, which is close to 0. Roller leveling can effectively eliminate bending in the plate, but there are regions in the head and tail of the plate, where roller leveling is not effective. The non-leveling region length is about 2 times that of the roller space. This study proposes a quasi-static plate-leveling model, which makes it possible to analyze the dynamic straightening process using a curvature integration method. It also makes it possible to analyze the straightening process of a plate with random curvature distribution.
[1] W Grimm, J Korth, W Kohler. Ilsenburg heavy-plate mill: Modernisation of the mill stand area and of the hot-plate leveler. Iron Steel Review, 2008, 51(9): 11.
[2] V Philippaus, S Mailllard. Modern levelers for advanced plate grade. Iron Steel Review, 2009, 52(10): 144.
[3] H Z Xu, K Liu, X H Peng, et al. Research of the image processing in dynamic flatness detection based on improved laser triangular method. Academic Journal of Xi'an Jiaotong University, 2008, 20(3): 168-171.
[4] F Cui. Straightening and straightening machine. 2nd ed. Beijing: Metallurgy Industry Press, 2002. (in Chinese)
[5] A R He, D Z Liu, C Liu. Research on roller straightening mechanical behavior of plastic hardening material. Journal of Mechanical Engineering, 2016, 52(18): 85-91. (in Chinese)
[6] Z Y Ma, L F Ma, R J Wang, et al. Study on control strategies of two-roll straightening for bar high precision straightening. Journal of Mechanical Engineering, 2017, 53(20): 77-88. (in Chinese)
[7] Q H Fan, H Zhang, X C Jiang. Leveling theory and experiment study on high strength steel plate of excavator working arm. Journal of Mechanical Engineering, 2017, 53(8): 82-90. (in Chinese)
[8] G C Yu, J Zhao, R Ma, et al. Uniform curvature theorem by reciprocating bending and its experimental verification. Journal of Mechanical Engineering, 2016, 52(18): 57-63. (in Chinese)
[9] J Zhao, H Q Cao, P P Zhan, et al. Pure bending equivalent principle for over-bend straightening and its experimental verification. Journal of Mechanical Engineering, 2012, 48(8): 28-33. (in Chinese)
[10] Z Q Zhang, Y H Yan, H L Yang. Research of section deformation of brazier effect in continuous straightening a thin-walled tube. Journal of Mechanical Engineering, 2015, 51(10): 62-68. (in Chinese)
[11] Z Q Zhang, Y H Yan, H L Yang. The straightening curvature-radius model for the thin-walled tube and its validation. Journal of Mechanical Engineering, 2013, 49(21): 160-167. (in Chinese)
[12] Y Zang, H G Wang, F L Cui. Elastic-plasticity analyze of bending deflection on section roller straightening. Journal of Mechanical Engineering, 2005, 41(11): 47-52. (in Chinese)
[13] B Guan, Y Zang, X N Pang, et al. Stress distribution and reverse bending behavior of section during roller leveling process. Journal of Central South University (Science and Technology), 2012, 43(5): 1740-1745.
[14] C L Zhou. Simulation and mathematical model on hot plate roller leveling. Shenyang: Northeastern University, 2006. (in Chinese)
[15] D Y Liu, A R He, H B Wang, et al. Reverse bending research of leveling on plastic hardening material. Journal of Mechanical Engineering, 2015, 51(8): 76-82. (in Chinese)
[16] M Grüber, G Hirt. A strategy for the controlled setting of flatness and residual stress distribution in sheet metals via roller levelling. Procedia Engineering, 2017, 207: 1332-1337.
[17] M Laugwitz, S Seuren, M Jochum, et al. Development of levelling strategies for heavy plates via controlled FE models. Procedia Engineering, 2017, 207: 1349-1354.
[18] H L Gui, Q Li, Q X Huang. The influence of bauschinger effect in straightening process. Mathematical Problems in Engineering, 2015(4): 1-5.
[19] H L Gui, Q Li, Y Li, P Li, Q X Huang. Analysis of rolled piece deformation in straightening process using Fm-Bem. Journal of Marine Science and Technology-Taiwan, 2014(22): 550-556.
[20] Q D Zhang, S Zhou, X F Zhang, et al. Analytic modeling and corroborating by FEM of tension leveling process of thin buckled steel strip. Journal of Mechanical Engineering, 2015, 51(2): 49-57. (in Chinese)
[21] H Huh, H W Lee, R P Sang, et al. The parametric process design of tension levelling with an elasto-plastic finite element method. Journal of Materials Processing Technology, 2001, 113(1): 714-719.
[22] N Mathieu, R Dimitriou, A Parrico, et al. Flatness defects after bridle rolls: a numerical analysis of leveling. International Journal of Material Forming, 2013, 6(2): 255-266.
[23] J Yoon. Numerical simulation of continuous tension leveling process of thin strip steel and its application. Journal of Iron and Steel Research, 2007, 14(6): 8-13.
[24] C Betegón Biempica, J J del Coz Díaz, P J Garcia Nieto, et al. Nonlinear analysis of residual stresses in a rail manufacturing process by FEM. Applied Mathematical Modelling, 2009, 33: 34-53.
[25] K Kadota, R Maeda. A model of analysis of curvature in leveling process-numeric study of roller leveling process. Jpn. Soc. Technol. Plast., 1993, 34: 481-486.
[26] T Higo, H Matsumoto, S Ogawa. Effects of numerical expression of stress-stain curve on curvature of material of roller leveling process. Jpn. Soc. Technol. Plast., 2002, 43(496): 439-443.
[27] J A Xue. Theoretical analysis for plate leveling process and its control system. Shenyang: Northeastern University, 2009. (in Chinese)
[28] Z F Liu, Y Q Wang, X C Yan. A new model for the plate leveling process based on curvature integration method. International Journal of Mechanical Sciences, 2012, 54: 213-224.
[29] L Cui, Q Q Shi, X H Liu, et al. Residual curvature of longitudinal profile plate roller in leveling process. Journal of Iron and Steel Research, 2013, 20(10): 23-27.
[30] B Guan, Y Zang, D P Wu, et al. Stress-inheriting behavior of H-beam during roller straightening process. Journal of Materials Processing Technology, 2017, 244: 253-272.
