Roll profile design for shaped wire rolling with high aspect ratio
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DOI 10.1007/s12206-020-0813-0
Journal of Mechanical Science and Technology 34 (9) 2020 Original Article DOI 10.1007/s12206-020-0813-0 Keywords: · Multi-stage cold rolling · Shaped wire · Roll profile design · High aspect ratio
Correspondence to: Dae-Cheol Ko [email protected]
Citation: Kim, J.-H., Kim, J.-H., Lee, K.-H., Moon, Y.-H., Ko, D.-C. (2020). Roll profile design for shaped wire rolling with high aspect ratio. Journal of Mechanical Science and Technology 34 (9) (2020) 3609~3615. http://doi.org/10.1007/s12206-020-0813-0
Received March 17th, 2020 Revised
June 15th, 2020
Accepted July 12th, 2020 † Recommended by Editor Chongdu Cho
Roll profile design for shaped wire rolling with high aspect ratio Jeong-Hun Kim1, Jae-Hong Kim2, Kyung-Hun Lee3, Young-Hoon Moon4 and Dae-Cheol Ko5,6 1
Precision Manufacturing Systems Division, Pusan National University, Busan 46241, Korea, Engineering Research Center of Innovative Technology on Advanced Forming, Pusan National Univer3 sity, Busan 46241, Korea, Division of Marine Engineering, Korea Marine and Ocean University, Busan 4 49112, Korea, School of Mechanical Engineering, Pusan National University, Busan 46241, Korea, 5 Graduate School of Convergence Science, Pusan National University, Busan 46241, Korea, 6 Department of Nanomechatronics Engineering, Pusan National University, Busan 46241, Korea 2
Abstract
For a shape rolling process of products with a high aspect ratio, its width does not spread sufficiently, frequently resulting in the unfilling phenomenon in the width direction. This paper proposes a roll profile design for the shape rolling process; this design method improves the dimensional accuracy of a shape wire with a high aspect ratio. From among the products produced by the shape rolling process in industrial sites, those with aspect ratios of ≥ 3.3 were selected in this study, and finite element (FE) simulation of the shape rolling process was conducted to verify the effectiveness of proposed method. The results of the FE simulation showed that the proposed design method was effective in performing the rolling process for shapes with high aspect ratios. In addition, the effectiveness of the proposed method was verified by conducting an experiment for bridge-valve wire by using plasticine. The experimental results showed that target shapes were obtained with an unfilling rate as low as 0.23 % for the cross-sectional area.
1. Introduction
© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2020
The rolling process is mainly used for either ferrous or nonferrous metal and is classified into cold, warm, and hot rolling of wire or sheet. For the hot rolling process, materials are plastically de-formed above their recrystallization temperature. The recrystallization keeps the materials from strain hardening. Therefore, the hot rolling process permits high deformation than cold rolling and is favorable to control the width spread in the rolling process in contrast with cold working. For the cold rolling p
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