Abstract
The paper deals with numerical analysis of the process of roller leveling of long products. The problem of multiple elastic plastic bending is solved by a program in Matlab, which is based on the Finite Element Method. The aim is to provide a simple, user friendly tool, capable of quick and reliable analysis of the process without the necessity to work with large multipurpose FEM packages. Direct solution of the problem is formulated, starting from the roll intermeshing and product geometry. Roller loading, product deflection, curvature and plastification are the output parameters of the program. With fast and reliable solution of the direct problem, optimal setting of the leveling process will be sought in an iterative process.
Highlights
Principal idea of all types of leveling processes is based on repeated elastic plastic bending, which results in redistribution of residual stress with the aim of minimization of final curvature of the product
Principal role is played by the relation between the intermeshing of leveling rollers and appropriate product curvature distribution, which leads to optimal distribution of residual stress and minimal output curvature
The last diagram shows the distribution of residual stress over the cross section of the bar after leaving the machine
Summary
Principal idea of all types of leveling processes is based on repeated elastic plastic bending, which results in redistribution of residual stress with the aim of minimization of final curvature of the product. Principal role is played by the relation between the intermeshing of leveling rollers and appropriate product curvature distribution, which leads to optimal distribution of residual stress and minimal output curvature. This problem is complicated due to its inherent nonlinearity, dependence on loading history, instability and sensitivity to material cyclic plasticity characteristics [1], [2]. Why a number of simpler computational models for quick and simple analysis of the leveling process were formulated They are based on the integration of curvature of the leveled product, starting from the bending curvature on each roller.
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