Asymmetric three-roller sheet-bending systems in steel-pipe production

Shinkin, V. N.

doi:10.3103/s0967091217040106

Cited by 23 publications

(10 citation statements)

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“…In the design of leveler equipment, the task of determining the strength characteristics of leveling is highlighted. In the paper [21], a mathematical method is proposed for determining the forces and moments during cold bending of a thick sheet on three-roll sheet bending systems. Calculations allow to determine the reaction of the roll supporting arms, the residual stress, the proportion of plastic deformation across the sheet thickness and the relative deformation of the sheet longitudinal surface fibers during bending as a function of the roll radius, distance between the rolls, sheet drafting by the upper roll, sheet thickness, Young's modulus, yield strength, and hardening coefficient of steel sheet.…”

Section: State Of the Art And Literature Reviewmentioning

confidence: 99%

Research and simulation of the sheet leveling machine manufacturing capabilities

Gribkov

Kovalenko

Hurkovskaya

2022

Int J Adv Manuf Technol

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One of the main tasks to determine the technological settings of the sheet leveling machine (leveler) is to identify the maximum roll overlap. In the well-known works on the study of sheet metal-roll leveling, the overlaps are set on the basis of experimental data, that is applicable for the leveling sheets from material with the 800 MPa yield strength. But for materials with a higher yield strength additional research is required. The purpose of this work is to establish criteria affecting the maximum allowable overlap for the working rolls by the leveler and to determine the dependencies for the most rational working rolls adjustment. When solving the set tasks, developed by the authors, a numerical analytical mathematical model of the leveling process was used as an objective function, that allows to determine the energy-power characteristics and the sheet curvature after leveling, depending on the individual settings of the leveler rolls. Within the framework of studies, an algorithm of a mathematical model was developed that allows to determine the leveler technological settings necessary for correcting the longitudinal curvature and comes down to determining the aligning coordinates for each of the movable rolls depending on the known characteristics of the metal being processed, the leveler geometric parameters, and the permissible value of the sheet residual curvature after leveling. In consequence of studying the influence of the working rolls setup on the sheet metal-roll quality during leveling on a multi-roll leveling machine, the laws for the rational rolls positioning were established. The linear and sinusoidal laws were identified as optimal ones. Boundary factors were also established as affecting the maximum overlap of the rolls. These factors included the condition of the pickup and the condition of the rolls strength. Using the example of implementing the developed finite element model of the sheet leveling process at the leveler of NKMZ (Ukraine), it was found that the pickup condition has a dominant influence when leveling sheets with a thickness of less than 6 mm, and with larger thicknesses the condition of the rolls strength is prevailing. With a decrease in the yield strength of the material or the width of the sheets, this ratio will be redistributed towards the pickup condition.

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Section: State Of the Art And Literature Reviewmentioning

confidence: 99%

Research and simulation of the sheet leveling machine manufacturing capabilities

Gribkov

Kovalenko

Hurkovskaya

2022

Int J Adv Manuf Technol

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“…As schematically shown in Figure 1, the inner roller only moves up and down and it is idle (that is, it is not driven by a motor), while the outer rollers are driven to rotate but they are stagnant (that is, they do not move upward or downward). By displacement of the inner roller toward the plate, it moves down to the point where the pinch pressure applied to the bending plate was set at a certain pressure [5]. As graphically shown in Figure 2, the difference in four-roller bending machines is not only the number of rollers but also the motion of the outer (side) rollers.…”

Section: Roll Bending Processmentioning

confidence: 99%

“…Springback concept and its analytical estimation in a metal forming [26] for its compensation in practice in die industry is of paramount importance in general as well as in the metal plate bending through both three-roller and four roller bending machines in particular. Springback can be defined as the elastically driven change of shape that occurs after deforming a plate at loading stage and then the plate tends to return to its original shape at unloading stage [21] and it partially returns due to the elasto-plastic deformation [5].…”

Section: Roll Bending Processmentioning

confidence: 99%

“…The pipelines are required to flawlessly convey liquid or gas without any leakage to a long distance thanks to new technological developments on plate bending process in recent decades. Three roll pyramids [1,2] and asymmetric machines [3][4][5] and four roll machines [6,7] have been developed to bend plates into cylinders, tanks, and pipes. Pipe, tank, or any large-sized cylindrical metal product manufacturers commonly choose four roll plate bending machines (Figure 2) because they have better efficiency compared to three roller machines.…”

Section: Introductionmentioning

confidence: 99%

“…Tailor et-al [11] investigated the effects of top roller and of rolling speed on bending quality by using an explicit dynamic FEA model in Hypermesh/Ls-Dyna. The four roll plate bending procedures in one pass using one of the side rolls without pre-bending have been modeled more widely asymmetric-three roller models [3,5]. Gavrilescu et al [14,15] attempted to analytically and numerically model a pyramid three roll bending process.…”

Section: Introductionmentioning

confidence: 99%

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Explicit dynamics finite element analyses of asymmetrical roll bending process

Kamas¹,

SARIKAYA²

2021

International Advanced Researches and Engineering Journal

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In this article, results obtained from a preliminary study that contains a set of explicit dynamics finite element analyses of a metal plate bending process are presented through 3D asymmetrical three roller models. ANSYS Ls-Dyna explicit dynamics finite element (ED-FEA) preprocessor and solver were used to carry out dynamic simulations. Explicit dynamics of a low-velocity process such as the roll-bending of a metal plate is a computationally expensive method. Since plastic deformation occurs on the plate in addition to elastic flexure to eventually possess a circular geometry, the plate material is considered a non-linear material. In this particular study, an aluminum plate was modeled with the Bilinear Kinematic Hardening model including plasticity parameters such as the tangent modulus. A very significant parameter called the mass scaling factor was taken into account to be able to define a specific time-step that was used to determine the computation time interval and the total temporal cost. However, exaggerated reduction of the computation time results in unphysical consequences. The results were presented before and after redesigning the lower and side rolls having a convex geometry and the peripheral velocity of upper roll rotation was decreased to minimize the distortion that occurred on the pre-bent side walls of the aluminum plate.

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