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A numerical approach to robust in-line control of roll forming processes
journal contribution
posted on 2012-01-01, 00:00 authored by J H Wiebenga, Matthias WeissMatthias Weiss, Bernard RolfeBernard Rolfe, T Van Den BoogaardThe 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 metamodels 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.
History
Journal
Steel research internationalSeason
Special issue : metal forming 2012Pagination
727 - 730Publisher
Wiley-VCHLocation
Chichester, Eng.ISSN
1611-3683Language
engNotes
This special issue is part of the 14th steel research international conference, 16-19 Sep. 2012, Krakow, Poland.Publication classification
C Journal article; C1.1 Refereed article in a scholarly journalCopyright notice
2012, Wiley-VCHUsage metrics
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