The Selection of Leveler Parameters Using FEM Simulation

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Manufacturing Processes

Background:

• Sheet metal waviness after unwinding from coils is a common manufacturing defect.
• Existing methods for waviness reduction require precise parameter selection for roll pre-levelers.
• Hot-rolled steel, specifically S235JR + AR grade, is widely used and susceptible to waviness.

Purpose of the Study:

• To determine optimal parameters for a roll pre-leveler to minimize sheet metal waviness.
• To develop and validate a mathematical model for predicting straightening performance.
• To improve the accuracy of numerical simulations for sheet metal leveling.

Main Methods:

• Utilized Finite Element Method (FEM) based numerical simulations.
• Developed a mathematical model to determine optimal straightening roll arrangements.
• Employed 3D laser scanning to create accurate geometric models of real sheet metal for simulations.

Main Results:

• Successfully identified key parameters for effective sheet metal waviness reduction.
• The developed mathematical model accurately predicted the necessary roll arrangements.
• Numerical simulations using real sheet metal models demonstrated increased accuracy in predicting straightening outcomes.

Conclusions:

• The optimized roll pre-leveler parameters effectively reduce sheet metal waviness.
• The integration of 3D laser scanning with FEM simulations provides a highly accurate approach for parameter selection.
• This research offers a validated methodology for improving the quality of hot-rolled steel sheets.