Effect of roll gap adjustment on exit cross sectional shape in groove rolling—Experimental and FE analysis

Byon, S.M.,Na, D.H.,Lee, Y. Elsevier 2009 Journal of materials processing technology Vol.209 No.9

<P><B>Abstract</B></P><P>We machined work roll with groove worn down as well as groove with no wear. We then performed a pilot hot rod rolling test at temperature of 1000°C using plain carbon steel (0.1% C) as the roll gap decreases from reference roll gap (6.5mm) to 3.5mm. To understand better the effect of roll gap (i.e., section height) adjustment on the exit cross sectional area (ECSA) variation of workpiece in a two-stand groove rolling process with wear is considered, we carried out a series of three dimensional finite element analysis. Results reveal that variation of ECSA is almost linearly proportional to roll gap change while the roll gap decreases from reference roll gap (6.5mm) to 3.5mm. In oval groove rolling, the exit cross sectional shape and area predicted by FEA is in a good agreement with those measured. In round groove rolling, however, some deviations between FEA and experiment are observed because of roll groove geometry coupled with cross sectional shape of incoming workpiece. In the two-stand groove rolling, the effect of roll gap adjustment at each stand on the exit cross section of workpiece is somewhat different, in comparison with single-stand groove rolling. The roll gap adjustment at the previous stand has a more influence on the ECSA of workpiece than that of the next stand.</P>

Design of Roll Profile for LM-Guide Block in Horizontal- Vertical Shape Rolling by 3D-EFA

이상진,이경훈,김병민 한국정밀공학회 2015 International Journal of Precision Engineering and Vol.16 No.4

In this paper, the design method for intermediate rolls has been developed to manufacture a linear motion (LM) guide block inhorizontal-vertical (H-V) shape rolling, based on the three-dimensional electric field analysis (3D-EFA). This design method canpredict appropriate cross-sections of roll profile at each pass based on the initial and final shapes. 3D-EFA simulations are performedseparately for the horizontal and vertical rolling passes to obtain roll profiles from equipotential lines. The roll profiles obtained basedon 3D-EFA are simulated by the commercial program Deform 3D, and are the reselected by compensating for the area of the errorfrom the equipotential lines. For convenience of field work and reducing strain concentration of the products, the roll profiles for thefirst and second passes are modified to be flat rolls because the roll profiles are almost rectangular. The effectiveness of the proposeddesign method is verified experimentally using AISI4120 steel for H-V shape rolling. From the experimental results, some over- andunder-filling ate the roll gap are observed for the final pass. However the dimensional errors are within ±0.3 mm, and no crackingor shearing is observed. The proposed design method will improve the efficiency of the design process by reducing time and costs.

자유회전 테일핀의 Roll Lock-in 현상 예측 연구

양영록(Young Rok Yang),조태환(Tae Hwan Cho),명노신(Rho Shin Myong) 한국항공우주학회 2010 韓國航空宇宙學會誌 Vol.38 No.9

본 논문은 자유회전 테일핀을 갖는 커나드 유도 미사일에 대해 Falanga의 회전율 계산식을 자유회전 테일핀에 적용하여 자유회전 테일핀의 roll lock-in 현상을 예측하였다. 예측 결과의 정확도를 확인하기 위하여 Blair의 풍동시험 결과와 비교하여 검증하였다. 자유회전 테일핀의 회전율 계산 시에 필요한 테일핀의 롤링 모멘트는 풍동시험 결과를 이용하였고 롤 댐핑 모멘트는 missile DATCOM을 이용하여 계산하였다. 이를 자유회전 테일핀의 회전율 계산식에 대입하여 자유회전 테일핀의 회전율 및 Roll lock-in 현상을 예측하였으며 풍동시험 결과와 비교하였다. 검증결과, 자유회전 테일핀의 회전율 및 Roll lock-in 현상 예측 결과가 풍동시험 결과와 잘 일치하는 것을 확인 할 수 있었다. This paper investigated the roll lock-in phenomena of a canard-controlled missile with freely spinning tailfins by applying Falanga’s roll-rate equation. To confirm and validate the accuracy of the results of the roll-rate and roll lock-in prediction for freely spinning tailfins, the results were compared with Blair's wind tunnel test data. For calculation of the roll-rate of freely spinning tailfins, rolling moment coefficients of the tailfins were obtained from the wind tunnel test data and roll-damping coefficients were calculated by missile DATCOM. The roll-rate and roll lock-in of the freely spinning tailfins were calculated by applying these values to the roll-rate equation for freely spinning tailfins. The calculation results showed good agreement with the wind tunnel test data, and the roll lock-in could be anticipated as well.

Experimental Study for Roll Gap Adjustment due to Roll Wear in Single-Stand Rolling and Multi-Stand Rolling Test

변상민,박흥식,이영석 대한기계학회 2008 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.22 No.5

To investigate a correlation between the amount of wear and roll gap (pass height) adjustment, we performed a sin-gle-stand reversible pilot groove rolling test as well as rolling test in an actual rod mill. In case of the pilot rolling test, we designed wear contour (profile) and machined it on the original roll groove (i.e., roll groove with no wear) to make the roll groove worn down. For the actual rod mill test, we developed a measuring device which can detect the actual wear profile. To determine the amount of roll gap adjustment, we propose a model for equivalent roll gap decrement which re-duces the increased exit cross sectional area due to wear. We applied the proposed model to multi-stand rolling (rough-ing train of POSCO No. 2 Rod Mill) as well as single-stand reversible rolling. The wear profile of rolls worn down at each stand in mill yard was measured at different roll tonnage. The pilot hot rolling test shows that variation of exit cross sectional area is almost linearly proportional to roll gap change while the roll gap decreases from reference roll gap (6.5m) to 3.5mm. In an actual rod mill which has con-secutive rolling system, relationship between tonage (total amount of tons that the produced rod weighs) and roll gap shape of incoming workpiece.

롤생산방식 유연회로기판의 레이저 드릴링 고속화 요소기술

라웅재 ( Woong-jae Ra ),최환영 ( Hwan Young Choi ) 한국실천공학교육학회 2023 실천공학교육논문지 Vol.15 No.1

Roll to Roll (이하 RTR)로 연결된 유연회로기판(이하 FPCB)에서 일정한 장력을 유지하여 안정적인 홀 가공이 가능하게 하는 Dancer Roll System를 경량화하고 서보모터를 활용한 토크 제어를 통해 기존 방식 FPCB RTR에서는 대응 불가능하였던 중력가 속도의 2배가 되는(이하 2.0G) 가속도의 고속 가공이 가능하도록 요소기술과 성능 지표를 제시한다. 기존 마그넷 클러치 방식 RTR에서는 달성이 불가능하였던 높은 회전수와 발열 문제, 낮은 토크 문제등을 마그네슘 소재를 이용한 Roll의 경량 가공법 개발과 서보모터의 토크 제어 알고리즘 개발을 통하여 해결하여 FPCB에 균일한 장력을 제공하고 토크 안정성을 높인다. 본 연구에서 개발한 요소 기술로 인해 Dancer Roll의 반응속도가 개선되어 목표한 고속화를 달성하였다. Authors report the performance indicator of Roll to Roll MC (hereinafter referred to as RTR) through experiment that it is possible to process 2.0G acceleration, which cannot be coped with in the existing FPCB RTR, by reducing the weight of the Dancer roll system and controlling the torque using the servo motor. Proposed dancer roll system provides uniform tension to FPCB by solving problems such as high rotation speed, heat generation, and low torque, which were impossible to achieve with the conventional magnet clutch type RTR. Through the development of a lightweight processing method for rolls using magnesium material and the development of a torque control algorithm for servo motor, torque stability also increased. Due to the enabling technology developed in this study, the reaction speed of the dancer roll was improved and the target speed was achieved as well.

압연온도 및 어닐링 온도에 따른 5052합금의 미세조직 및 기계적 성질

강의구,남원종 대한금속·재료학회 2019 대한금속·재료학회지 Vol.57 No.10

The microstructural evolution and corresponding mechanical properties of 5052 Al alloys with different deformation temperatures and post-deformation annealing conditions were investigated. The warmrolled alloy showed higher strength and elongation than the cold-rolled and cryo-rolled alloys. The improved strength and ductility of warm rolled alloys is attributed to the formation of fine precipitates and a higher degree of recovery during rolling. The formation of precipitates and the occurrence of dynamic recovery during the warm-rolling process were confirmed by the absence of the first two peaks in DSC curves of warm-rolled alloys. In particular, it was found that the application of cryo-rolling combined with warm-rolling at 448K increased tensile strength and yield strength without a decrease of ductility. This notable increase of strength is attributed to the increased dislocation density during cryo-rolling and the subsequent formation of fine precipitates at dislocations during warm-rolling. The contribution of fine precipitates and fully recovered microstructures, during cryo-rolling, warm-rolling, and subsequent annealing enhances the effective combination of strength and elongation. The ultra-fine grained 5052 Al alloy with high strength (405 MPa) and ductility (11.4% elongation) could be achieved by a combination of cryo-rolling with warm-rolling (448 K) and subsequent static annealing at 448 K.

세기변조방사선치료에서 Pitch와 Roll 변화에 따른 선량전달 정확성 평가

정창영,배선명,이동형,민순기,강태영,백금문,Jeong, Chang Young,Bae, Sun Myung,Lee, Dong Hyung,Min, Soon Ki,Kang, Tae Young,Baek, Geum Mun 대한방사선치료학회 2014 대한방사선치료학회지 Vol.26 No.2

목 적 : 세기변조방사선치료에서(Intensity modulated radiation therapy,IMRT) 6D robotic couch의 pitch 와 roll 변화에 따른 선량전달의 정확성을 평가하고자 한다. 대상 및 방법 : Trilogy(Varian Medical Systems, USA)와 6D robotic couch(ProturaTM 1.4, CIVCO, USA)를 사용하여 골반부위의 세기변조방사선치료를 진행한 14명의 환자를 대상으로 영상유도 시 발생한 pitch 와 roll 방향의 오차 값과 발생빈도를 분석하였다. 오차의 변화에 따른 선량전달 정확성의 차이를 평가하기 위해 pitch 와 roll의 변화가 $0^{\circ}$인 상태의 측정치를 기준으로 각각 $1.0^{\circ}$, $1.5^{\circ}$, $2.0^{\circ}$, $2.5^{\circ}$로 변화시킨 경우에 대하여 2차원 이온전리함 배열 검출기(I'mRT Matrixx, IBA Dosimetry,Germany)와 MultiCube Phantom(IBA Dosimetry, Germany)를 이용하여 측정 후 감마지수(3 mm, 3%)의 비교평가를 실시하였다. 실험에는 Dynamic Multi-Leaf Collimator의 sliding window기법을 사용한 3명의 자궁경부암 치료계획을 적용하였다. 결 과 : 대상 환자의 영상(3D/3D Match 78건, 2D/2D match 79건)을 분석한 결과 pitch 와 roll의 평균 오차값은 $0.9^{\circ}{\pm}0.7$, $0.5^{\circ}{\pm}0.6$, 최대 값은 $2.8^{\circ}$, $2.0^{\circ}$로 분석되었고, 최소값은 pitch 와 roll 모두 $0^{\circ}$으로 나타났다. 각각의 조건에서 측정된 선량전달에 대하여 감마지수를 이용하여 비교한 결과, pitch가 $1.0^{\circ}$, $1.5^{\circ}$, $2.0^{\circ}$, $2.5^{\circ}$일 때 gamma pass rate의 평균은 각각 97.75%, 96.65%, 94.38%, 90.91%, roll의 경우 $1.0^{\circ}$, $1.5^{\circ}$, $2.0^{\circ}$, $2.5^{\circ}$에서 평균 93.68%, 93.05%, 87.77%, 84.96%로 나타났고, pitch 와 roll을 동시에 변화시킨 경우 $1.0^{\circ}$, $1.5^{\circ}$, $2.0^{\circ}$에서 평균 94.90%, 92.37%, 87.88%의 결과 값을 얻었다. 결 론 : 대상 환자의 영상 유도 시 pitch 와 roll의 오차 발생률은 전체 치료 횟수에서 각각 82.20%, 72.20%로 분석되었고, 감마지수를 통해 오차 값이 커질수록 선량전달의 정확성이 낮아진다는 것을 확인할 수 있었다. 세기변조방사선치료 시 선량전달의 정확성을 높이기 위해서는 정확한 자세잡이와 더블어 적절한 영상유도를 통해서 pitch 와 roll 방향으로 발생할 수 있는 오차를 줄이도록 노력해야 할 것으로 사료된다. Purpose : The purpose of this study is to verify the accuracy of dose delivery according to the pitch and roll rotational setup error with 6D robotic couch in Intensity Modulated Radiation Therapy (IMRT) for pelvic region in patients. Materials and Methods : Trilogy(Varian, USA) and 6D robotic couch(ProturaTM 1.4, CIVCO, USA) were used to measure and analyze the rotational setup error of 14 patients (157 setup cases) for pelvic region. The total 157 Images(CBCT 78, Radiography 79) were used to calculate the mean value and the incidence of pitch and roll rotational setup error with Microsoft Office Excel 2007. The measured data (3 mm, 3%) at the reference angle ($0^{\circ}$) without couch rotation of pitch and roll direction was compared to the others at different pitch and roll angles ($1^{\circ}$, $1.5^{\circ}$, $2^{\circ}$, $2.5^{\circ}$) to verify the accuracy of dose delivery by using 2D array ionization chamber (I'mRT Matrixx, IBA Dosimetry, Germany) and MultiCube Phantom(IBA Dosimetry, Germany). Result from the data, gamma index was evaluated. Results : The mean values of pitch and roll rotational setup error were $0.9^{\circ}{\pm}0.7$, $0.5^{\circ}{\pm}0.6$. The maximum values of them were $2.8^{\circ}$, $2.0^{\circ}$. All of the minimum values were zero. The mean values of gamma pass rate at four different pitch angles ($1^{\circ}$, $1.5^{\circ}$, $2^{\circ}$, $2.5^{\circ}$) were 97.75%, 96.65%, 94.38% and 90.91%. The mean values of gamma pass rate at four different roll angles ($1^{\circ}$, $1.5^{\circ}$, $2^{\circ}$, $2.5^{\circ}$) were 93.68%, 93.05%, 87.77% and 84.96%. when the same angles ($1^{\circ}$, $1.5^{\circ}$, $2^{\circ}$) of pitch and roll were applied simultaneously, The mean values of each angle were 94.90%, 92.37% and 87.88%, respectively. Conclusion : As a result of this study, it was able to recognize that the accuracy of dose delivered is lowered gradually as pitch and roll increases. In order to increase the accuracy of delivered dose, therefore, it is recommended to perform IGRT or correct patient's position in the pitch and roll direction, to improve the quality of treatment.

HIP(열간 등방압) 공정을 이용한 압연 롤 제조 공정의 해석 메커니즘

김웅(W. Kim) 한국소성·가공학회 2023 소성가공 : 한국소성가공학회지 Vol.32 No.3

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.

Design and Shape Control Ability Simulation of New Generation Varying Contact Length Backup Roll in Hot Rolling

Wenquan Sun,Jian Shao,Anrui He 보안공학연구지원센터 2016 International Journal of Multimedia and Ubiquitous Vol.11 No.4

Backup roll technology plays an important role in hot strip mill shape control. Varying contact length backup roll (VCR) technology in hot strip mill can increase transverse stiffness of loaded gap, heighten control effect of roll bending, and improve distribution of contact force between backup roll and work roll. However it appears to lack coordination with high-order curve work roll. A new objective function of new generation varying contact length backup roll (VCR plus) design curve is established with considering high-order work roll contour, and simulation is carried out to verify the effectiveness of VCR plus by a two dimensional variable thickness finite element method. The result shows that distribution of contact force between backup roll and work roll is more even in VCR plus technology, and which can extend the useful life of backup roll.

철도차량 롤 특성에 대한 고찰

김필환(Kim Pil-Hwan) 한국철도학회 1998 한국철도학회 학술발표대회논문집 Vol.- No.-

The roll characteristic of railway vehicle is an important factor that affects the roll-over of vehicle and lateral ride comfort of passenger. Generally the roll characteristics of railway vehicle is defined by the term of roll-coefficient, s, which represents the ratio of incline of carbody to that of rail-cant. The limit values of roll coefficient recommended in UIC are 0.4 for coach without pantograph and 0.15 for vehicle with pantograph. The roll coefficient can be calculated by VAMPIRE that is the well-known commercial software for analysis of dynamic behavior of railway vehicle. The value of roll coefficient is effected by height of gravity center of carbody, stiffness of primary and secondary suspension and etc. The calculated roll-coefficient for electric locomotive and passenger coach is 0.12 and 0.77 respectively. The additional equipment such as anti-roll bar is considered in order to decrease roll-coefficient of passenger coach. In relation to roll characteristics, the analysis for roll-over due to wind is also performed. The results show that roll-characteristics affect the roll-over of vehicle.