Comparative Analysis of the Application of Five-, Seven- and Nine-Roll Sheet Straightening Using Numerical Tools

The paper presents the results of a numerical analysis of the roller straightening process. The study evaluated straightening systems consisting of 5, 7, and 9 rollers. The assessment was based on real data obtained under industrial conditions. The research involved the use of two widely used structural steel grades, namely S235JR and S500MC. As part of the study, an analysis of the anisotropy of sheet properties within the coil volume was also conducted. Additionally, the surface topography of the sheets was analyzed and subsequently used in the numerical simulations. The inclusion of real data regarding both material anisotropy and actual geometry allowed for an increase in calculation accuracy. Furthermore, investigations were carried out to analyze the method of implementing material data into the mathematical model. The work also analyzed the accuracy of the obtained numerical results based on material data from the traditional method of introducing material information in the form of an approximated curve. Numerical studies confirmed by a physical test developed by the authors, which can be easily implemented in industrial conditions, confirmed the research assumptions and literature data. The main advantage of the presented solutions is their relative ease of implementation and use in manufacturing facilities with limited research facilities.