An analysis, design, and improvement methodology for shape-rolling processes and procedures for the compensation of dies.

摘要

This dissertation concerns the development of a systematic methodology for the analysis, design, and the improvement of shape rolling processes. While many general methodologies exist for the design process, none currently exist specifically for nonsteady state shape rolling processes such as the pinch and roll process. An extensive review of the relevant technical literature has shown this to be true. This dissertation is the first in depth investigation of non-steady state shape rolling processes to produce analysis methods, design tools, and improvement and efficiency procedures.; The technical literature review revealed that only the simplest rolling cases, such as flat sheet rolling or oval rolling, had been investigated. In contrast to these simple cases, no such informational databases are available for complex geometry and tapered products. The only improvement or design methods available for the more complex processes were the antiquated and costly trial and error procedures.; To investigate this process a unique data acquisition system was developed to monitor the process and to provide an apparatus for several designed experiments. This industrialized data acquisition system also became an integral part of the new, efficient, and accurate setup procedures that replaced an expensive trial and error process. This process was also investigated using the industrial engineering tool of designed experiments, which were carried out in both laboratory and industrial settings. The process was also investigated using finite element simulations to evaluate material deformations occurring during the process.; The successful application of the new methodology significantly improved the process by the creation of tools and procedures that increase the efficiency and accuracy of many manufacturing aspects. The knowledge gained during the investigation led to the creation of new die modification procedures, which consist of an experimental and analysis process and four modification methods. These four methods concern, section line slip, press discrepancies, elastic die deflections, and the warping of section lines.