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The application of modelling techniques to identify material properties for cost effective and high quality profiling. / Stuart J Gilmartin
Swansea University Author: Stuart J Gilmartin
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Zinc and organically coated strip steels are products of Corus Colors, which are supplied to the roll forming industry and profiled for a variety of applications, including building cladding and composite floor decking. Many profile designs include complex roll geometry which promotes intense deform...
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Zinc and organically coated strip steels are products of Corus Colors, which are supplied to the roll forming industry and profiled for a variety of applications, including building cladding and composite floor decking. Many profile designs include complex roll geometry which promotes intense deformation and as a consequence can create a number of defects within the steel strip. Cracking, wavy edges and spring-back are three of the more common reoccurring problems. To overcome such defects within the production line when they occur, simple procedures are carried out by experienced line operators. One method is to adjust the clearance between the upper and lower rolls of the problematic roll stand on either the outboard or inboard side of the production line. In recent years the potential of Finite Element Modelling (FEM) has been realised for the simulation of such processes in both 2D and 3D. Due to advances in computer graphics and processing, the use of 3D FEM packages to simulate the effects on material properties within a roll forming line is becoming an area of high interest within the profiling industry. Studies in this report have focused on using ABAQUS FEM software to simulate in 3D, profiling stands within a production line used to create a trapezoidal profile using HPS200 (Colorcoat) steel. Particular attention was given to the variables set during creation of the simulation, such as friction coefficients, roll clearance and speed of the rotating rolls used to transport the strip. A plant trial was conducted to determine the profile measurements of the strip at different stages of the process which were then used to perform a validation with the simulation model.
College of Engineering