Skip to main content
SpringerLink
Log in

Design of roll profile in shape rolling by 3D-EFA

  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

The design of roll profile in shape rolling is important as a key role in improving product quality, such as dimensional accuracy, ensuring defect-free property and good mechanical properties. In this study, the design method using three dimensional electric field analysis (3D-EFA) is proposed to design intermediate roll profiles for the shape rolling. The shape of equi-potential lines as intermediate roll profiles could be generated between the initial shape and final shape by 3D-EFA. The intermediate roll profile for each pass is selected among a numerous equi-potential lines, and the effectiveness of the selected roll profiles is verified by FEsimulation. The over- or under-filling area is calculated from the result of FE-simulation, another equi-potential line is selected to compensate for the area of the error. The proposed method is applied to a shape like rear door hinge that is generally designed by the trial and error method to show the applicability of this method for various shapes. The lab-scale experiment is carried out with plasticine, and the results are within the allowable tolerance of ±0.5 mm. Therefore, the proposed method can be widely used to design roll profiles for complex shapes thereby reducing the design time.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wusatowski, Z., “Fundamentals of Rolling,” Pergamon Press, pp. 501–530, 1969.

    Google Scholar 

  2. British Steel Corporation, “Roll Pass Design,” pp. 15–41, 1976.

    Google Scholar 

  3. Saito, Y., Moriga, M., and Kato, K., “Calculation of Spread and Elongation of Bars in Rolling Pass Sequences, Square-Oval, Square-Diamond and Round-Oval,” Journal of Iron Steel Institute of Japan, Vol. 63, No. 12, pp. 1819–1827, 1977.

    Google Scholar 

  4. Saito, Y., Takahashi, Y., Moriga, M., and Kato, K., “A New Method for Calculating Deformation and Force Parameters in Steel Rod Rolling and Its Application to Roll Pass Design,” The Japan Society for Technology of Plasticity, Vol. 24, No. 273, pp. 1070–1077, 1983.

    Google Scholar 

  5. Shinokura, T. and Takai, K., “A New Method for Calculating Spread in Rod Rolling,” Journal of Applied Metalworking, Vol. 2, No. 2, pp. 94–99, 1982.

    Article  Google Scholar 

  6. Lee, Y. S., Kim, B. M., and Kim, D. H., “Prediction Model of the Exit Cross Sectional Shape of Workpiece in Round-Oval-Round Pass Rolling,” International Journal of KSME, Vol. 16, No. 6, pp. 785–798, 2002.

    Google Scholar 

  7. Lee, S. J., Kim, S. M., Ko, D. C., and Kim, B. M., “Design of Roll Profile in Shape Rolling of an Irregular Angle Bar by the Modified Butterfly Method,” Int. J. Precis. Eng. Manuf., Vol. 14, No. 1, pp. 93–102, 2013.

    Article  Google Scholar 

  8. Lee, S. R., Lee, Y. K., Park, C. H., and Yang, D. Y., “A New Method of Preform Design in Hot Forging by using Electric Field Theory,” International Journal of Mechanical Sciences, Vol. 44, No. 4, pp. 773–792, 2002.

    Article  MATH  Google Scholar 

  9. Lee, S. K., Lee, J. E., Kim, S. M., and Kim, B. M., “Design of Intermediate Die Shape of Multistage Profile Drawing for Linear Motion Guide,” Journal of Mechanical Science and Technology, Vol. 24, No. 12, pp. 2539–2544, 2010.

    Article  Google Scholar 

  10. Kim, S. M., “A Study on the Process Design of Shape Drawing Process for Steering Spline,” M.Sc. Thesis, Department of Precision Manufacturing System Division, School of Mechanical Engineering, Pusan National University, 2010.

    Google Scholar 

  11. Lee, S. J., Ko, D. C., Lee, S. K., and Kim, B. M., “A New Design of Roll Profile In Shape Rolling Process of Automobile Door Hinge using Electric Field Analysis,” Steel Research International, pp. 35–38, 2012.

    Google Scholar 

  12. Lee, J. H., Kim, Y. H., Bae, W. B., and Lee, W. H., “A Study on Development of Model Materials Showing Similar Flow Characteristics of Hot Mild Steel at Various Temperatures,” Transactions of the KSME, Vol. 17, No. 5, pp. 1161–1171, 1993.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Precision Manufacturing System Division, Pusan National University, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Sang-Jin Lee

  2. PNU-IFAM Joint Research Center, Pusan National University, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Kyung-Hun Lee

  3. Industrial Liaison Innovation Center, Pusan National University, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Dae-Cheol Ko

  4. Ultimate Manufacturing Technology R&BD Group, Korea Institute of Industrial Technology, 302 Techno sunhwan-ro, Yuga-myeon, Dalseong-gun, Daegu, 711-880, South Korea

    Sang-Kon Lee

  5. School of Mechanical Engineering, Pusan National University, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Byung-Min Kim

Authors
  1. Sang-Jin Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kyung-Hun Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dae-Cheol Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sang-Kon Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Byung-Min Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Byung-Min Kim.

Additional information

Sang-Jin Lee and Kyung-Hun Lee contributed equally to this work

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lee, SJ., Lee, KH., Ko, DC. et al. Design of roll profile in shape rolling by 3D-EFA. Int. J. Precis. Eng. Manuf. 16, 701–706 (2015). https://doi.org/10.1007/s12541-015-0093-2

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-015-0093-2

Keywords

Search

Navigation