An analytical study of optimal roller intermeshes for the plate leveling process

Abstract

Leveling process is usually used to minimize the plate defects including flatness imperfections and uniformity of internal stress in the plate industry. Roller intermeshes are important parameters in the leveling process to ensure the high-quality leveled plate. Some current researches treat the plate as a simple beam and ignore the stress superimposed effect to study how to set the roller intermeshes. This article presents an analytical optimization model to search the optimal entry and exit intermeshes for each incoming plate with consideration of the relationship between the roller intermeshes and bending curvatures during the whole leveling process. The optimization model was solved and the results were verified with production data. The relationship between the optimal roller intermeshes and plate thickness, yield stress, and Young’s modulus were discussed in details. It was found out that the roller intermeshes can be set the same for different incoming plates but with equal elastic limit curvature. A four-dimensional database of optimal roller intermeshes about different elastic limit curvature, expected plastic strain ratios, and roller spaces was built. The roller intermeshes can be quickly tracked in less than 1 s as long as the thickness, yield stress, and Young’s modulus of incoming plate and roller space are given according to the database so that it can be used effectively on the leveling production line.

The influence of multi-point roller-dies on the shape deviation differences of profile in flexible stretch-bending forming

“…The FSB is a forming method in which the whole die is discretized into several roller dies which can be adjusted independently at different positions, so as to form different target shapes. 16–22 This forming method can be used for multiple purposes with one machine, reducing production costs, and improving production efficiency. Figure 1 is the schematic diagram of the overall die stretch bending forming and multi-point die stretch bending forming.…”

Effect of Roller Levelling on Tensile Properties of Aluminum Sheets

“…The roller levelling process has been analyzed in several publications. In the earliest research, mechanical models were established; some good examples can be found in [1][2][3][4][5][6][7][8][9]. Ref.…”

“…Refs. [5][6][7] considered the initial sheet curvature and applied an iterative method for calculating the effective contact points between rolls and sheet. Refs.…”

Optimization Model of Process Parameters for Full-Plate Long-Roll Straightening considering Equipment Bounce

“…Xue et al [11][12][13] suggested that the contact angle has a cumulative effect throughout the straightening process, and this cumulative effect hurts the residual curvature, which was verified by numerical simulation for calculation. Liu et al [14][15][16] used numerical algorithms to solve for the curvature and concluded that the original curvature has a large effect on the contact angle of the first few rolls. Yin et al [17] studied the section steel-leveling process on a flexible roller system based on springback theory.…”