The quality of roll formed products is known to be highly sensitive and dependent on the process parameters and thus the unavoidable variations of these parameters during mass production. To maintain a constant high product quality, a new roll former with an adjustable final roll forming stand is developed at Deakin University enabling the continuous compensation for possible shape defects. In this work, a numerical approach to robust in-line control of the roll forming of a V-section profile is presented, combining the aspects of robust process design and in-line compensation methods. A numerical study is performed to determine the relationship between controllable process settings and uncontrollable variation of incoming material properties with respect to the common product defects longitudinal bow and springback. The computationally expensive non-linear FE simulations used in this study are subsequently replaced by metamod-els based on efficient Single Response Surfaces. Using these metamodels, the optimal setting for the adjustable stand is determined with robust optimization techniques and the effect on product quality analyzed. It is shown that the subsequent adjustment of the final roll stand position leads to a significantly improved product quality by preventing product defects and minimizing the deteriorating effects of scattering variables.
|Number of pages
|Steel research international
|Published - 16 Sept 2012
|14th International Conference on Metal Forming, Metal Forming 2012 - AGH University of Science and Technology, Krakow, Poland
Duration: 16 Sept 2012 → 19 Sept 2012
Conference number: 14