Abstract
Higher quality requirements by customers demand higher precision and accuracy from manufacturing processes. Application oriented preparation of semi-finished materials is key for subsequent forming operations, therefore, straightening machines are employed. Straightening strengthens the material by increasing plastic deformation by means of strain hardening, resulting in undesirable reduction in formability when processing high strength materials, in particular. Conventional roll-type straightening machines process either bars or strips. This is achieved upon passing material between rolls arranged in two staggered rows. However, conventional straightening processes do not adapt to the local varying distortion of coiled strips. Innovative, self-correcting process control techniques, which adapt to the initial geometric characteristics of the strip, present a promising approach to fix this issue through optimization of the leveling process. Here, an innovative strategy to improve straightening of high strength steel materials (1.4310) is presented. This implements optimized leveling, adding minimal plastic deformation and, thus, strain hardening. To operate an intelligent straightening machine, a reliable online measurement of the surface defects is fundamentally essential. The MagnaTest, which is developed for material testing, is made feasible for such purposes after calibrating for curvature measurement. Preliminary results are promising in regards to measuring the curvature online, so that the following straightening process can be close loop controlled. The bending measurement is linked to open/closed loop control, therefore providing an optimal straightening result in regards to formability, leveling, and reduced strain hardening.
Highlights
As a result of increasing globalization and rising quality requirements, the steel and metal processing industry is facing growing cost and innovation pressure to meet market demands
The subject of this paper is to demonstrate the possibility of measuring the curvature of a steel strip under tensile loading superposition
Since optical and force sensors are unsuitable for this purpose, a magnetic induction testing setup was used
Summary
As a result of increasing globalization and rising quality requirements, the steel and metal processing industry is facing growing cost and innovation pressure to meet market demands. The especially narrow tolerances and dimensional accuracy required in processing high-strength wire materials present economic and ecological challenges. These are best addressed by improving the processability of high-strength steel spring materials using straightening devices with set-up assistance systems to significantly increase their potential to compete with other materials in the market. These system configurations achieve a higher amount of acceptable formed parts, reducing the quantity of rejects, requiring less material and financial resources. The set up assistance systems require additional information regarding material behavior during straightening as well as the straightening process in general
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