Journal articles: 'Roll-to-Roll Manufacturing Process'

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Lazarus, Nathan, and Gabriel L. Smith. "Laser Folding in a Roll-to-Roll Manufacturing Process." Lasers in Manufacturing and Materials Processing 5, no. 3 (July 7, 2018): 237–47. http://dx.doi.org/10.1007/s40516-018-0064-4.

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Kodihalli Shivaprakash, Nischay, Jinde Zhang, Artee Panwar, Carol Barry, Quoc Truong, and Joey Mead. "Continuous manufacturing of reentrant structures via roll-to-roll process." Journal of Applied Polymer Science 136, no. 1 (September 23, 2018): 46980. http://dx.doi.org/10.1002/app.46980.

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Wang, Xiaojia, HongMei Zang, and Peter Li. "48.5: Roll-to-Roll Manufacturing Process for Full Color Electrophoretic Film." SID Symposium Digest of Technical Papers 37, no. 1 (2006): 1587. http://dx.doi.org/10.1889/1.2433301.

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Wang, Dongxiang, Jacqueline Hauptmann, and Christian May. "OLED Manufacturing on Flexible Substrates Towards Roll-to-Roll." MRS Advances 4, no. 24 (2019): 1367–75. http://dx.doi.org/10.1557/adv.2019.62.

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ABSTRACTLarge area lighting OLEDs manufactured in a Roll-to-Roll (R2R) fashion enable the well-longed production capability with considerably high throughput based on flexible substrates, hence largely reduced OLED manufacturing cost. This paper will outline the present status of R2R OLED fabrication on ultra-thin glass with the focus on transparent OLED devices and how to perform segmentation by printing of silver- and dielectric pastes. Ultra-thin glass (UTG) is laminated on a PET film to avoid fabrication interruptions when glass cracks occur during the Roll-to-Roll process. The R2R fabricated flexible OLEDs also show key-values comparable to conventional OLEDs fabricated on small rigid glass in lab-scale.

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Yu, Dan, Dirk Beckelmann, Michael Opsölder, Bruno Schäfer, Karsten Moh, René Hensel, Peter de Oliveira, and Eduard Arzt. "Roll-to-Roll Manufacturing of Micropatterned Adhesives by Template Compression." Materials 12, no. 1 (December 29, 2018): 97. http://dx.doi.org/10.3390/ma12010097.

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For the next generation of handling systems, reversible adhesion enabled by micropatterned dry adhesives exhibits high potential. The versatility of polymeric micropatterns in handling objects made from various materials has been demonstrated by several groups. However, specimens reported in most studies have been restricted to the laboratory scale. Upscaling the size and quantity of micropatterned adhesives is the next step to enable successful technology transfer. Towards this aim, we introduce a continuous roll-to-roll replication process for fabrication of high-performance, mushroom-shaped micropatterned dry adhesives. The micropatterns were made from UV-curable polyurethane acrylates. To ensure the integrity of the complex structure during the fabrication process, flexible templates were used. The compression between the template and the wet prepolymer coating was investigated to optimize replication results without structural failures, and hence, to improve adhesion. As a result, we obtained micropatterned adhesive tapes, 10 cm in width and several meters in length, with adhesion strength about 250 kPa to glass, suitable for a wide range of applications.

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Tahir, Usama, Jin Il Kim, Shama Javeed, Amin Khaliq, Jun-Hyun Kim, Doo-In Kim, and Myung Yung Jeong. "Process Optimization for Manufacturing Functional Nanosurfaces by Roll-to-Roll Nanoimprint Lithography." Nanomaterials 12, no. 3 (January 29, 2022): 480. http://dx.doi.org/10.3390/nano12030480.

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Roll-to-roll nanoimprint lithography (RTR-NIL) is a low-cost and continuous fabrication process for large-area functional films. However, the partial ultraviolet (UV) resin filling obstructs the ongoing production process. This study incorporates UV resin filling process into the nanopillars and nanopores by using RTR-NIL. A multiphase numerical model with a sliding mesh method is proposed in this study to show the actual phenomena of imprint mold rotation and feeding of UV resin on the polyethylene terephthalate (PET) substrate. The implementation of UV resin filling under environmental conditions was performed by utilizing the open-channel (OC) boundary conditions. The numerical model was solved by using the explicit volume of fluid (VOF) scheme to compute the filling on each node of the computational domain. The effects of different processing parameters were investigated through the proposed numerical model such as imprinting speed (IS), contact angles (CAs), viscosity, initial thickness of the PET, and supporting roll diameter. A good agreement was found between numerical simulations and experimental results. The proposed numerical model gives better insights of the filling process for the mass production of functional surfaces with nanopillars and nanopores patterns for different applications on an industrial scale.

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Jo, Minho, Jongsu Lee, Seongyong Kim, Gyoujin Cho, Taik-Min Lee, and Changwoo Lee. "Web Unevenness Due to Thermal Deformation in the Roll-to-Roll Manufacturing Process." Applied Sciences 10, no. 23 (December 2, 2020): 8636. http://dx.doi.org/10.3390/app10238636.

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In roll-to-roll (R2R) processing, web uniformity is a crucial factor that can guarantee high coating quality. To understand web defects due to thermal deformation, we analyzed the effect of web unevenness on the coating quality of an yttria-stabilized zirconia (YSZ) layer, a brittle electrolyte of solid oxide fuel cells (SOFCs). We used finite-element analysis to study thermal and mechanical deformations at different drying temperature levels. A YSZ layer was also coated using R2R slot-die coating to observe the effect of web unevenness on coating quality. Web unevenness was generated by thermal deformation due to conduction and convection heat from the dryer. Because of varying web unevenness with time, the YSZ layer developed cracks. At higher drying temperatures, more coating defects with larger widths were generated. Results indicated that web unevenness at the coating section led to coating defects that could damage the SOFCs and decrease yield in the R2R process. Coating defects generated by web unevenness caused by convection and conduction heat should be considered in the high-volume production of brittle electrolytes using the R2R process.

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Smolka, Martin, Stephan Ruttloff, Dieter Nees, Christine Prietl, Valentin Satzinger, Bernhard Lamprecht, Philipp Hütter, et al. "High Throughput Roll-to-Roll Production of Microfluidic Chips." Proceedings 2, no. 13 (December 4, 2018): 1054. http://dx.doi.org/10.3390/proceedings2131054.

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A high throughput manufacturing process of microfluidic chips based on Roll-to-Roll imprinting is presented. With this procedure, microfluidic patterns can be produced on large area polymer substrates. The subsequent steps of inlet drilling, bonding and electrode printing are set-up on large area processes, too. Overall, this strategy allows highly parallelized processing of large numbers of chips—all costly steps of individual chip handling are avoided. The chips were used for the characterization of inorganic ions for soil nutrient analysis.

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Wang, Min-Wen, Wei-Chuang Lin, and Ming-Hsiao Lee. "Fabrication of flexible microlens array film using roll-to-roll process." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 227, no. 4 (April 2013): 543–50. http://dx.doi.org/10.1177/0954405413475940.

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Lee, Jongsu, Junhyeon Byeon, and Changwoo Lee. "Theories and Control Technologies for Web Handling in the Roll-to-Roll Manufacturing Process." International Journal of Precision Engineering and Manufacturing-Green Technology 7, no. 2 (January 4, 2020): 525–44. http://dx.doi.org/10.1007/s40684-019-00185-3.

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Noh, Jaehyun, Minho Jo, Hojin Jeon, Minjae Kim, Jeongdai Jo, and Changwoo Lee. "Web Wrinkle Defects due to Temperature Profile in Roll-to-Roll Manufacturing Systems." Polymers 15, no. 2 (January 15, 2023): 457. http://dx.doi.org/10.3390/polym15020457.

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The roll-to-roll manufacturing system is extensively used for mass producing products made of plastic, paper, and fabric in several traditional industries. When flexible substrates, also known as webs, are heated and transported inside the dryer, an inconsistent temperature distribution occurs on the material in the machine direction (MD) and cross-machine direction (CMD). If rollers are not aligned in parallel on the same plane in the roll-to-roll web handling process, or if roller misalignment exists, strain deviation occurs in the web, resulting in lateral displacement and web wrinkles. Therefore, this study examined a wrinkle, which is a thermal deformation that occurs when an inconsistent web temperature distribution is formed on the material inside a dryer. The changes in the elastic modulus and thermal expansion of the web were also examined. Experiments were conducted using a PET film, and its elastic modulus and thermal expansion were examined. The results showed that the presence of a web wrinkle defect can cause a thickness deviation in the functional layer manufactured on the web. Moreover, an appropriate operating speed should be set to reduce the CMD temperature deviation, thereby reducing instances of wrinkle defects.

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Jou, Jwo-Huei, Snehasis Sahoo, Deepak Kumar Dubey, Rohit Ashok Kumar Yadav, Sujith Sudheendran Swayamprabha, and Sudam Dhudaku Chavhan. "Molecule-based monochromatic and polychromatic OLEDs with wet-process feasibility." Journal of Materials Chemistry C 6, no. 43 (2018): 11492–518. http://dx.doi.org/10.1039/c8tc04203a.

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Tahir, Usama, Muhammad Ahmad Kamran, and Myung Yung Jeong. "Numerical Study on the Optimization of Roll-to-Roll Ultraviolet Imprint Lithography." Coatings 9, no. 9 (September 8, 2019): 573. http://dx.doi.org/10.3390/coatings9090573.

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Roll-to-roll ultraviolet (R2R-UV) imprinting is a low-cost and high-throughput method that includes the manufacturing of large-area functional films. However, the quality of the final product is obstructed by the bubble entrapment during the imprinting process. In this study, a multi-phase volume of fluid (VOF) numerical model was used to remove bubble entrapment during the R2R imprinting process, which covered all parameters. This new modified numerical model with open-channel boundary conditions was based on the single zone that contains the direct contact of UV resin with the imprinting mold during the filling process. In addition, this model simulated the UV resin filling into microcavities at the preceding and succeeding ends of the imprinting mold. Different patterns of imprinting mold were considered to enhance the fidelity of R2R-UV imprinting for the comprehensive analysis. The experimental results validated through numerical simulations revealed that the bubble entrapment can be controlled by varying various parameters such as speed of the imprinting system, viscosity, contact angles, and pattern shape. The proposed model may be useful for a continuous bubble-free R2R imprinting process in industrial applications that includes flexible displays and micro/nano-optics.

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Shin, Jong Gye, Sun il Won, Cheol Ho Ryu, Hyunjune Yim, and Jang Hyun Lee. "Object-Oriented Development of an Integrated System for Manufacturing Information of Roll Bending Process." Journal of Ship Production 18, no. 02 (May 1, 2002): 86–91. http://dx.doi.org/10.5957/jsp.2002.18.2.86.

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An integrated software system was developed for the manufacturing information of the roll bending process for ship hull pieces. To this end, the information flow in the process was studied and designed using the object-oriented method. Separate program modules, obtained by introducing new approaches or modifying existing methods, were integrated to yield a software system that can provide all the manufacturing information required for the roll bending of hull pieces of general shape. The information includes roll orientations, roll lines, roll region, and the center roller movement. Two examples are presented to demonstrate the performance of the developed software. The software developed in this work is expected to provide a solid basis for the automated and efficient fabrication of hull pieces. Also, the object-oriented models developed here will be of great use for further study of ship production.

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Boutiette, Amber L., Cristoffer Toothaker, Bailey Corless, Chouaib Boukaftane, and Caitlin Howell. "3D printing direct to industrial roll-to-roll casting for fast prototyping of scalable microfluidic systems." PLOS ONE 15, no. 12 (December 28, 2020): e0244324. http://dx.doi.org/10.1371/journal.pone.0244324.

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Microfluidic technologies have enormous potential to offer breakthrough solutions across a wide range of applications. However, the rate of scale-up and commercialization of these technologies has lagged significantly behind promising breakthrough developments in the lab, due at least in part to the problems presented by transitioning from benchtop fabrication methods to mass-manufacturing. In this work, we develop and validate a method to create functional microfluidic prototype devices using 3D printed masters in an industrial-scale roll-to-roll continuous casting process. There were no significant difference in mixing performance between the roll-to-roll cast devices and the PDMS controls in fluidic mixing tests. Furthermore, the casting process provided information on the suitability of the prototype microfluidic patterns for scale-up. This work represents an important step in the realization of high-volume prototyping and manufacturing of microfluidic patterns for use across a broad range of applications.

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Jung, Jaehan. "Continuous manufacturing of 3D patterned hybrid film via a roll-to-roll process with UV curing." Modern Physics Letters B 34, no. 07n09 (March 16, 2020): 2040039. http://dx.doi.org/10.1142/s0217984920400394.

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A strategy for continuous fabrication of a microscale 3D-patterned hybrid composite film composed of alumina and acrylate resin was developed using roll-to-roll production. Conventional thermal curing was replaced with a UV curing procedure to facilitate rapid and economical processing. A seamless engraved soft urethane mold was first produced using a patterned metal roll. Subsequently, alumina and acrylate resin were cured on the engraved mold via UV irradiation to produce patterned hybrid films. The dispersion of alumina particles in acylate resin was enhanced by utilizing amine acrylate. Photopolymerization was measured using Fourier-transform infrared spectroscopy. The morphology of the soft engraved mold and the patterned hybrid film was investigated using scanning electron microscopy.

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Gwag, Jin-Seog, In-Yung Han, Kwang-Soo Bae, Hong Choi, Kyunghwa Sohn, and Jae-Hoon Kim. "P-71: Substrate Adhesion Technique Using Thermosetting Resin to Apply Roll-to-Roll Process to Manufacturing of LCDs." SID Symposium Digest of Technical Papers 39, no. 1 (2008): 1454. http://dx.doi.org/10.1889/1.3069426.

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Watari, Hisaki, Ryoji Nakamura, R. Paisern, Nobuhio Koga, and Keith Davey. "Mechanical Properties and Metallurgical Qualities of Magnesium Alloy Sheets Manufactured by Twin-Roll Casting." Key Engineering Materials 345-346 (August 2007): 165–68. http://dx.doi.org/10.4028/www.scientific.net/kem.345-346.165.

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This paper is concerned with a manufacturing process and technology to facilitate the economical manufacture of high-quality magnesium alloy sheets. Magnesium alloys AZ31, AZ61, AM60 and AZ91 were used to investigate the appropriate anufacturing conditions for use in twin-roll strip casting. Temperatures of the molten materials and roll speeds were varied to find the appropriate manufacturing conditions. The effects of manufacturing conditions on possible forming were clarified in terms of roll speeds and roll gaps between upper and lower rolls. In addition, microscopic observation of the microstructure of the finished casting was performed. It was clarified that a magnesium sheet of 2.5 to 4.5mm thickness could be produced at a speed of 20 m/min by a horizontal copper roll caster. It was also found that the cast magnesium sheet of AZ31, AZ61, AM60 and AZ91 manufactured by roll strip casting could be used for plastic forming if the appropriate magnesium sheets were produced after the roll casting process. By a warm deep drawing test, it also demonstrated that a limiting drawing ratio of 2.4 was possible in the case of AZ91 sheet that was difficult to be manufactured by conventional extrusion process or DC casting and hot-rolling process for magesium alloy sheets with high aluminium contents.

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Jung, Dong Won. "Quadrilateral Shape Rib Forming by Roll Forming Process." Applied Mechanics and Materials 878 (February 2018): 296–301. http://dx.doi.org/10.4028/www.scientific.net/amm.878.296.

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The roll forming is one of the simplest manufacturing processes for meeting the continued needs of various industries. The roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for making structural components. In order to reduce the thinning of the sheet product, traditionally the roll forming has been suggested instead of the stamping process. The increased product performance, higher quality, and the lowest cost with other advantages have made roll forming processes suitable to form any shapes in the sheets. In this numerical study, a Finite Element Method is applied to estimate the stress, strain and the thickness distribution in the metal sheet with quadrilateral shape, ribs formed by the 11 steps roll forming processes using a validated model. The metal sheet of size 1,000 × 662 × 1.6 mm taken from SGHS steel was used to form the quadrilateral shape ribs on it by the roll forming process. The simulation results of the 11 step roll forming show that the stress distribution was almost uniform and the strain distribution was concentrated on the ribs. The maximum thinning strain was observed in the order of 15.5 % in the middle rib region possibly due to the least degree of freedom of the material.

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Muladi, Nandy, Kusnadi, and Asep Erik. "ESTIMATION OF HARD PLAIN RUBBER ROLL MANUFACTURING PROCESS TIME USING LINEAR REGRESSION METHOD." Jurnal Teknovasi 9, no. 01 (April 1, 2022): 1–18. http://dx.doi.org/10.55445/jt.v9i01.33.

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Competition in the industrial world today requires producers to compete in providing good quality products with short production times and relatively low production costs. This relates to production machines which have an important role to produce products with good quality. PT. Voith Paper Rolls Indonesia is a service and manufacturing company engaged in roll repair and manufacture of roll cover materials. One of the production processes carried out during roll repair is the turning process which is carried out twice. In the turning process, there is often a significant time difference between the actual time and the estimated time obtained from the existing formulation. Therefore, this report will focus on efforts to improve the calculation formulation for the estimation of turning process time on lathe A on hard plain rubber roll by analyzing the effect of surface area on processing time using a simple linear regression method through the IBM SPSS application.

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Muladi, Nandy, Kusnadi, and Asep Erik. "ESTIMATION OF HARD PLAIN RUBBER ROLL MANUFACTURING PROCESS TIME USING LINEAR REGRESSION METHOD." Jurnal Teknovasi 9, no. 01 (April 1, 2022): 1–18. http://dx.doi.org/10.55445/jt.v9i01.33.

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Competition in the industrial world today requires producers to compete in providing good quality products with short production times and relatively low production costs. This relates to production machines which have an important role to produce products with good quality. PT. Voith Paper Rolls Indonesia is a service and manufacturing company engaged in roll repair and manufacture of roll cover materials. One of the production processes carried out during roll repair is the turning process which is carried out twice. In the turning process, there is often a significant time difference between the actual time and the estimated time obtained from the existing formulation. Therefore, this report will focus on efforts to improve the calculation formulation for the estimation of turning process time on lathe A on hard plain rubber roll by analyzing the effect of surface area on processing time using a simple linear regression method through the IBM SPSS application.

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Burkitt, Daniel, Peter Greenwood, Katherine Hooper, David Richards, Vasil Stoichkov, David Beynon, Eifion Jewell, and Trystan Watson. "Meniscus Guide Slot-Die Coating For Roll-to-Roll Perovskite Solar Cells." MRS Advances 4, no. 24 (2019): 1399–407. http://dx.doi.org/10.1557/adv.2019.79.

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Abstract:Roll-to-roll slot-die coating with a meniscus guide is used to deposit several layers in a P-I-N perovskite solar cell stack, including the perovskite layer. The use of various length meniscus guides as part of the slot-die head allows controlled coating of these layers at a common coating speed. The length of meniscus guide used is optimised and related to the rheology of the coated ink and appropriate choice of meniscus guide length provides a way to avoid flooding of the coated area and improve coating definition. Initial coating trial results suggest the low-flow limit of slot-die coating is still applicable when using a meniscus guide, which is an important and previously unreported observation, application of this theory to meniscus guide coating provides a useful tool for rapidly determining the appropriate coating conditions that can be used as part of a manufacturing process. This is further explored through the deposition of perovskite solar cells by roll-to-roll slot-die coating. The perovskite layer is deposited using a sequential slot-die deposition process using a low toxicity dimethyl sulfoxide ink for the lead iodide layer, it is found that increasing the drying oven temperature and air flow rate can be used to improve the uniformity of the layer but this can also result in deformation of the plastic substrate. Functioning perovskite solar cells are demonstrated using this technique, but a large variation is found between device performances which is attributed to the poor uniformity of the perovskite layer and damage caused to the substrate by excessive heating.

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Steinhoff, Bryan Dennis, James Dong, Olha Mashtalir, Ramin Amin-Sanayei, Kunlun Hong, and Jianlin Li. "(Invited) High Throughput Solvent-Free Manufacturing of Battery Electrodes." ECS Meeting Abstracts MA2022-02, no. 6 (October 9, 2022): 633. http://dx.doi.org/10.1149/ma2022-026633mtgabs.

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Research into the manufacturing of LIB electrodes is constantly evolving with new active materials, improved binders, and improved drying techniques to more efficiently produce high-quality electrodes. However, the one constant in all these endeavors is that electrode research and manufacture still generally rely on a slurry-coating process, where large amounts of potentially toxic solvents are necessary for slurry production. As such, solvent-free, also known as dry-process (DP), electrode processing has been proposed to solve the conventional lithium-ion battery electrodes fabrication disadvantages, such as high equipment costs for solvent reclamation, currently seen in industry. Currently, the solvent-free, state-of-the-art electrodes use polytetrafluoroethylene (PTFE) as a binder and the PTFE is fibrillized and dispersed in the dry powder mixture using a jet mill. One key solvent-free electrode shortcoming is that PTFE is not electrochemically stable for the anode, traditionally resulting in initial capacity losses of greater than 30% and poor mechanical strength, effectively limiting solvent-free processing to cathodes. A second shortcoming is that solvent-free electrodes generally require the addition of fibrillization promoters or processing steps that add cost and detract from performance by limiting active material content in the final electrodes. In a recent development, Navitas and its internal partners of Cabot, Arkema, the University of Tennessee, Knoxville, and Oak Ridge National Laboratory have shown the capability to produce both solvent-free anodes and cathodes utilizing an advanced dry-electrode process (ADEP) that also enables high-throughput production of next generation battery electrodes. These electrodes have improved mechanical strength, sufficient to withstand roll-to-roll manufacturing, and the anodes demonstrate an initial capacity loss of less than 15%. The group has demonstrated roll-to-roll production of solvent-free electrodes at quasi-industry standard active material compositions (90-92%) without the reliance of previously used fibrillization promoters, even at reduced PTFE concentrations in the formulation. Navitas has recently demonstrated the large format lamination of the initially formed, or “free-standing,” electrodes after they have been produced in roll-to-roll manufacturing and the integration of solvent-free electrodes in dual-layer and multi-layer pouch cells using typical industry tooling and cell production techniques. Key words: solvent-free, dry-process, fibrillization, next generation lithium-ion batteries (NGLB), advanced dry-electrode process (ADEP), initial capacity loss, free-standing, roll-to-roll, pouch cell

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Lee, Jongsu, and Changwoo Lee. "Improvement of a Splicing Machine to Decrease Abrupt Tension Changes and Tail Defects during the Roll Exchange Process in a Roll-to-Roll Manufacturing System." International Journal of Precision Engineering and Manufacturing 19, no. 8 (August 2018): 1155–61. http://dx.doi.org/10.1007/s12541-018-0136-6.

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Farhadipour, Pedram, M. Sedighi, and Mohammad Heydari vini. "Using warm accumulative roll bonding method to produce Al-Al2O3 metal matrix composite." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 5 (April 2017): 889–96. http://dx.doi.org/10.1177/0954405417703421.

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In this study, warm accumulative roll bonding process has been used to produce metal matrix composite (Al/1% Al2O3). The microstructure and mechanical properties of composites have been studied after different warm accumulative roll bonding cycles by tensile test, Vickers micro-hardness test and scanning electron microscopy. The scanning electron microscopy results reveal that during higher warm accumulative roll bonding cycles, the layers of alumina particles are broken. It leads to the generation of elongated dense clusters with smaller sizes. This microstructure evolution leads to improve the hardness, strength and elongation during the accumulative roll bonding process. The results demonstrated that the dispersed alumina clusters improve both the strength and toughness of the composites. Also, an extra pass of cold rolling on the final warm accumulative roll bonding product shows the ability to obtain further strength. In general, warm accumulative roll bonding process would allow fabricating metal particle reinforced with high uniformity, good mechanical properties and high bonding strength.

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Byon, Sang Min, Yong-Hoon Roh, Zhaorui Yang, and Youngseog Lee. "A roll-bending approach to suppress the edge cracking of silicon steel in the cold rolling process." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, no. 1-2 (August 25, 2020): 112–24. http://dx.doi.org/10.1177/0954405420949221.

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The range of roll-bending that inhibits the edge cracking of high-silicon (3.0 wt%) steel strip during cold rolling was investigated by performing a pilot cold rolling test. In the rolling test, roll-bending was emulated by lathe-machining the work roll surface to be concave (corresponding to negative roll-bending) or convex (corresponding to positive roll-bending). Crack growth length that propagated during rolling and crack growth direction were measured. Three-dimensional finite element analysis coupled with ductile fracture criterion was conducted to predict the crack growth length and crack growth direction. The reliability of the finite element analysis was verified by comparing the predictions with measurements. A series of finite element simulations were then conducted with different levels of roll-bending, expressed as the ratio of the radius of curvature of work roll surface ( R) to its barrel length ( L).The difference between the measurements and the predictions of the crack growth length and crack growth direction was 6.5% and 8.3%, respectively, when the initial notch length was 6 mm. Even if a high reduction ratio for a given pass was applied to the silicon steel strip, edge cracking did not occur if the L/ R ratio was less than −0.15, with a negative value corresponding to a concave surface profile, representing negative bending.

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Groche, Peter, and Michael Henkelmann. "Dimensional Deviation of Roll Formed Components Made of High Strength Steel." Key Engineering Materials 344 (July 2007): 285–92. http://dx.doi.org/10.4028/www.scientific.net/kem.344.285.

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During the last half century roll forming has become a highly productive metal forming technology, well-established in the industry for the manufacturing of mass products. About 8 % of the annual world production of steel is processed by roll forming mills. Roll forming technology enables the manufacturing of profile-shaped products with an extremely wide spectrum of geometrical shapes. In lightweight construction, the utilization of roll-formed structures of high and ultra-high-strength steels has increased remarkably in the recent years. However, the application of those types of steel entails some disadvantages resulting in a decreasing forming capacity and enormous efforts to reach the required dimensional accuracy. Until a profile leaves the roll forming machine with the target quality, it is mostly necessary to align the forming rolls several times. Sometimes even design changes are required. This is the result of unreliable process planning. Furthermore, typical profile failures such as twist, flare and spring-back occur even stronger compared to mild steels. Nowadays, it is usual to control the dimensional accuracy of the profiles after the last forming stand. This kind of quality control has the following disadvantage: manufacturing errors are detected very late. Therefore, a continuous quality control process and an active manipulation during the forming process promise a large potential for an improvement of the dimensional accuracy and an increase of roll forming productivity.

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Cheng, Peifu, Nicole K. Moehring, Juan Carlos Idrobo, Ilia N. Ivanov, and Piran R. Kidambi. "Scalable synthesis of nanoporous atomically thin graphene membranes for dialysis and molecular separations via facile isopropanol-assisted hot lamination." Nanoscale 13, no. 5 (2021): 2825–37. http://dx.doi.org/10.1039/d0nr07384a.

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We report on a roll-to-roll manufacturing compatible isopropanol-assisted-hot-lamination process for facile fabrication of large-area nanoporous atomically thin graphene membranes (NATMs) for dialysis and molecular separations.

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Groche, Peter, Christian Mueller, and Lars Baeumer. "Verification of Numerical Roll Forming Loads with the Aid of Measurement Equipment." Advanced Materials Research 939 (May 2014): 373–80. http://dx.doi.org/10.4028/www.scientific.net/amr.939.373.

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Roll forming is an important forming process for profile manufacturing in mass production. The design of the process has an important influence on the quality of the products. Therefore, the knowledge of the occurring loads during the roll forming process, e.g. forces and pressures, is essential for the process design. However, the experimental determination of the occurring contact normal pressures in roll forming processes poses a challenge. Finite element simulations offer the potential to approximate contact normal loads and thus, enable a better process design. Nevertheless, due to simplifications of the numerical model, a realistic and reliable output of loads in roll forming is not possible. An enhanced numerical model could provide more valuable information. This paper will demonstrate the reproduction of realistic contact normal pressures and load forces in a roll forming simulation. To verify the numerical values, they will be compared to data gained by experiments.

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A. M., Tiara, Hyeokgyun Moon, Gyoujin Cho, and Jinkee Lee. "Fully roll-to-roll gravure printed electronics: challenges and the way to integrating logic gates." Japanese Journal of Applied Physics 61, SE (April 7, 2022): SE0802. http://dx.doi.org/10.35848/1347-4065/ac575e.

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Abstract Printed electronics have been considered to bring about the ICT (Information Communication Technology) revolution. The high-throughput production of the ultra-low-cost printed devices along with the level of integration of logic gates via an all roll-to-roll (R2R) printing method has been the major axes in the revolution. However, there have been certain concerns related to the integration of logic gates via the R2R printing methods. This review paper focuses on the key issues that must be resolved to maintain a uniform threshold voltage (V th) value, which can otherwise impede the commercial viability of such devices. Amongst the various factors contributing to the ΔV th value, the ink rheology, web handling, and the disparity in alignment amongst the drain-source electrodes and the gate electrodes due to the limitations of an overlay printing registration accuracy (OPRA) were reviewed to effectively control the variations during the R2R printing process, without including the material’s intrinsic instability factors. Accordingly, a unique design rule for the R2R printing foundry concept was introduced for manufacturing the devices with the available integration level of the logic gates, incorporating the printing parameters including ink rheology, ink transfer, web handling, and OPRA.

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Qiao, Zheng, Da Qu, Huiming Wang, Dongxu Wu, and Bo Wang. "Experimental investigation of the influence of chip interference on burr height in machining micro V-grooves on electroplated copper roll die." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 8 (September 26, 2016): 1491–97. http://dx.doi.org/10.1177/0954405416668927.

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The roll-to-roll imprinting technology is considered as the most promising process for manufacturing large-area microstructured surface in a high-precision, high-efficiency and low-cost way. However, the existence of cutting burr of microstructures on roll die will deteriorate the quality of microstructures on target surface in roll-to-roll imprinting processing. For electroplated copper material, this article presents the influence of chip interference on burr in cutting process. The parameter that illustrates the level of chip interference is deduced. The influences of cutting depth and included angle of V-shaped diamond tool on burr height of V-grooves are revealed by analyzing the chip interference. A series of experiments are carried out to verify the theoretical study. The results show good agreement between theoretical derivation and experimental analysis. The reason for chip interference of cutting process is made clear. Then, the optimal process of multi-step cutting process was given as the guidance to enhance the surface quality of micro V-grooves on electroplated copper roll die. With the optimal cutting parameters, the high-quality surface of micro-prism array is achieved.

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Watari, Hisaki, Yoshimasa Nishio, Ryoji Nakamura, Keith Davey, and Nobuhio Koga. "Microstructure and Mechanical Properties of High Aluminum Content Magnesium Alloys Fabricated by Twin-Roll Casting Process." Materials Science Forum 638-642 (January 2010): 1608–13. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.1608.

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This paper describes the twin roll casting technology of magnesium alloys that contains relatively high weight ratio of aluminum, such as AM60, AZ91 and AZ121. The cast magnesium alloy sheets were hot-rolled in an elevated temperature to investigate the appropriate hot-rolling conditions for producing high-quality strip using a purpose-built strip-casting mill. The influences of such process parameters as materials of roll, casting temperature, and roll speed are ascertained. A simple method of predicting the convection heat transfer coefficient between casting rolls and molten metal is introduced. The microstructure of the manufactured wrought alloy sheets was observed to investigate the effects of the hot-rolling and heat-treatment conditions on crystal growth in the cast products. It is found that manufacturing thin magnesium alloy sheet was possible at a roll speed of 110m/min by a vertical type roll caster. The grain size of the manufactured wrought magnesium alloys sheet was less than 30 micrometers due to rapid solidification in the proposed process.

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Park, Janghoon, Keehyun Shin, and Changwoo Lee. "Optimized design for anti-reflection coating process in roll-to-roll slot-die coating system." Robotics and Computer-Integrated Manufacturing 30, no. 5 (October 2014): 432–41. http://dx.doi.org/10.1016/j.rcim.2014.02.001.

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Huang, Chia-Sheng, Heng-Tien Lin, Guo-Shing Huang, Je-Ping Hu, Su-Tsai Lu, C. T. Liu, Sean Garner, et al. "58.2:Distinguished Paper: Roll-to-roll Process on Ultra-thin Flexible Glass for Manufacturing the Multi-Touch Sensor Panel." SID Symposium Digest of Technical Papers 44, no. 1 (June 2013): 807–9. http://dx.doi.org/10.1002/j.2168-0159.2013.tb06339.x.

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Wu, Qiang, Jim P. Zheng, Mary Hendrickson, and Edward J. Plichta. "Dry Process for Fabricating Low Cost and High Performance Electrode for Energy Storage Devices." MRS Advances 4, no. 15 (2019): 857–63. http://dx.doi.org/10.1557/adv.2019.29.

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AbstractWe report a roll-to-roll dry processing for making low cost and high performance electrodes for lithium-ion batteries (LIBs). Currently, the electrodes for LIBs are made with a slurry casting procedure (wet method). The dry electrode fabrication is a three-step process including: step 1 of uniformly mixing electrode materials powders comprising an active material, a carbonaceous conductor and the soft polymer binder; step 2 of forming a free-standing, continuous electrode film by pressing the mixed powders together through the gap between two rolls of a roll-mill; and step 3 of roll-to-roll laminating the electrode film onto a substrate such as a current collector. Compared with the conventional wet slurry electrode manufacturing method, the dry manufactural procedure and infrastructure are simpler, the production cost is lower, and the process eliminates volatile organic compound emission and is more environmentally friendly, and the ability of making thick (>120µm) electrodes with high tap density results in high energy density of final energy storage device. A prototype LIBs of LiNi0.6Mn0.2Co0.2O2 (NMC622)/graphite also has 230 Wh/ kg energy density.

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Mueller, Christian, Xun Gu, Lars Baeumer, and Peter Groche. "Influence of Friction on the Loads in a Roll Forming Simulation with Compliant Rolls." Key Engineering Materials 611-612 (May 2014): 436–43. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.436.

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Roll forming is an important economic forming process for manufacturing of profiles. For an optimal design of the process, it is important to determine the loads occurring during the forming process. Furthermore, the information of the load behavior enables an evaluation of the formability of the planned profiles with the chosen roll forming machine. An experimental determination of loads in roll forming processes requires a complex measurement setup in combination with a high amount of measurement devices. Hence, the analysis of roll loads by means of finite element simulation is of special interest. The use of roll forming simulations for the determination of geometrical outputs is state of the art. However, due to simplifications, a realistic and reliable output of roll loads in roll forming is impossible. Therefore, the compliance behavior under load and the frictional behavior have to be incorporated in the simulation model. The friction behavior in roll forming processes is presented to be very insignificant in literature. The value of the friction coefficients vary in a broad range. Due to lack of knowledge in the compliance behavior of the used stands, simulation models with rigid rolls are still state of the art. This paper will show the reproduction of realistic roll loads, e.g. torques and forces, in a roll forming simulation. Therefore, the friction coefficients of each roll-sheet metal contact will be gained experimentally and implemented in the numerical model. Furthermore, a characteristic compliance of the roll forming stands will be analyzed and also considered in the simulation. Finally, the influence of changing parameters, e.g. raise of the friction coefficients, on the roll loads will be investigated. To verify the simulation the numerical results will be compared to data gained by experiments.

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Yang, Sheng, Li Zhang, Hong Xu, and Li Wei Zhao. "Finite Element Analysis on the Roll Milling Process of Twisted Oblate Tube." Advanced Materials Research 97-101 (March 2010): 3065–69. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.3065.

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The roll milling process for manufacturing a twisted oblate tube was presented and applied in the forming of twisted oblate copper tube successfully. A finite element simulation of the roll milling process for forming a twisted oblate 1010 steel tube was implemented on the basis of the elastic-plastic explicit dynamic finite element method under the ANSYS/LS-DYNA environment. The simulation accuracy was verified by comparing the forming force from simulation with the experimental results. The forming effect, change curve of forming force, tube stress distribution and influences of forming parameters on forming force were investigated. The simulation results can be guidance to the manufacturing process improvement and manufacturing equipment design of the twisted oblate steel tube.

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Li, Yue, Shu Chen Yang, Mi Wang, and Guo Long Lu. "Elongation Rule of the Longitudinal Fiber of the Continuous Roll Forming Part." Materials Science Forum 921 (May 2018): 184–88. http://dx.doi.org/10.4028/www.scientific.net/msf.921.184.

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Continuous roll forming is a novel technique for low-cost, high-efficient manufacturing of three-dimensional surface part. Comparing with conventional continuous forming (using at least three rolls), continuous roll forming employs an upper and a lower flexible rolls to shape the sheet metal. The desired forming shape can be obtained by controlling the profile of the flexible roll and the gap between upper and lower flexible rolls. Modeling and simulation of the continuous roll forming process based on finite element analyses is established to investigate the elongation rule of the longitudinal fiber of the continuous roll forming part. The length of the longitudinal fiber at different positions across the thickness direction is discussed, and the mechanism of the longitudinal deformation is clarified. The following conclusions are obtained. When the flexible roll profile and the roll gap distribution meet certain conditions and make length of the longitudinal fiber linearly distributed, the longitudinal deformation of the sheet metal can be generated.

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Peng, Wen Fang, Qiang Li, and Yu Yan. "FEA Analysis on 600MPa TRIP Steel Variable Section Roll Forming with Protrusion and Hole." Advanced Materials Research 457-458 (January 2012): 299–303. http://dx.doi.org/10.4028/www.scientific.net/amr.457-458.299.

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Trip steel is broadly used in automobile manufacturing with its high strength and enhanced formability. For the variable section parts with protrusion and hole, roll forming is a kind of feasible way to realize continuous parts manufacturing, In the paper, with deep understanding of roll forming process and reasonable simplification, the FEM model of a multi-step variable section roll forming of 600MPa trip steel parts with protrusion and hole is established to analyze the mechanics and the deformation characteristics of the forming procedure. Equivalent stress, equivalent strain, sheet thickness and springback amount are extracted from the simulation result and studied comparatively, which is of great importance to understand the appearance of the forming defects. In addition, the forming load and torque of the rollers can also be obtained to guide the design of the variable section roll forming product line.

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Abrass, Ahmad, Thomas Kessler, and Peter Groche. "Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm." Key Engineering Materials 504-506 (February 2012): 857–62. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.857.

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For the manufacturing of large quantities of profile-shaped products, the roll forming process represents one of the most effective metal forming technologies. During this process, the sheet metal will be formed into a desired cross-sectional profile using successive pairs of forming rolls. This process is well known as a very complex process in industry because of the multiplicity of the process and design parameters. For that reason, the optimization of roll forming processes using numerical methods like the finite element method is very complex and time-consuming. In this paper, a numerical method will be introduced to accelerate the simulation and to optimize the roll forming process. The newly developed algorithm will be illustrated and validated by analyzing the roll forming process. The details of the FE-model and the numerical algorithm will be described. Furthermore, the results of the numerical simulation with and without the application of the numerical algorithms will be compared. Finally, the process will be optimized using the newly developed method.

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RAUSCHER, BORIS, MICHAEL TROMPETER, and A. ERMAN TEKKAYA. "MANUFACTURING AND FORMING OF PARTIALLY CLADDED DOUBLE BLANKS." Journal of Advanced Manufacturing Systems 07, no. 01 (June 2008): 33–36. http://dx.doi.org/10.1142/s0219686708001048.

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The paper presents the manufacturing and hydroforming of partially cladded double blanks. This novel, semi-finished product can be produced by partial cold roll-bonded cladding. By printing a separating layer onto the contact surface beforehand, cold roll-bonded cladding, defined blank areas remain unjoined which can be bulged during hydroforming to a complex part. Favorable advantages result from the time and cost effective continuous joining process and the extended potential for a material combination aimed at optimally adapted multi-layer composites. Experimental investigations could prove a good joining strength and assure that the cold roll-bonded cladding does not significantly decrease the formability of the cladded blank material. Considering a heat exchanger and a roof rail, the experimental investigations could prove the producibility of parts based on partially cladded blanks and have shown an adequate shape accuracy of the produced parts.

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Guo, Remn-Min. "Prediction of Strip Profile in Rolling Process Using Influence Coefficients and Boussinesq’s Equations." Journal of Manufacturing Science and Engineering 119, no. 2 (May 1, 1997): 220–26. http://dx.doi.org/10.1115/1.2831098.

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A simplified numerical method is proposed in this article to predict strip profile. The mill is simulated by beams (rolls) on the infinite elastic half space (between rolls and strip). The roll deflection and indentation are calculated using the influence coefficients and Boussinesq’s equations respectively. The roll contours in the contact zone can be expressed in terms of the influence coefficient and indentation matrices. Compatibility equations are derived by matching two surface profiles in the contact zone. Equilibrium equations ensure force and moment balance of the strip and each roll. A complete linear system is established by assembling compatibility and equilibrium equations. The contact rolling pressure distribution and the rigid motion of the roll chocks can be solved. Roll surface contours and strip profiles can be further calculated accordingly.

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Ren, Y., J. Dong, Y. Sun, A. Sedlmaier, Q. Guo, D. Zhang, and J. Yang. "Digitization of roll forming and its application." IOP Conference Series: Materials Science and Engineering 1270, no. 1 (December 1, 2022): 012010. http://dx.doi.org/10.1088/1757-899x/1270/1/012010.

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With the rapid development of metaverse and intelligent manufacturing, the requirement for the digitization of the traditional manufacturing process is a challenging task for industries. Roll forming is a highly efficient sheet metal forming process which can be widely been applied in a wide range of sectors, such as automotive, transportation, building other key sectors. However, this forming process is highly dependent on the experience of the on-site engineers. This paper presents a highly intelligent, flexible and self-adaption roll forming machine co-developed by the University of Electronic Science and Technology of China and data M. The machine consists of several flexible moving units controlled by codded stepper motors with a decent control system. Moreover, a high-performing artificial intelligence algorithm achieved from a systematic machine learning training process is integrated into this machine. The algorithm has already been use to predict and control the forming process to achieve a high-quality product. Data collection on a large scale and integrated sensors lead to an increased understanding of the process and provide the basis to develop self-optimizing roll forming machines, increasing the productivity, quality and predictability of the roll forming process. The application of digital twin and machine learning techniques is used to predict and reduce the amount of springback in the product. The first high-strength steel parts successfully manufactured with this new forming concept are presented.

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Günther, Till, Nicolas Billot, Jörg Schuster, Joscha Schnell, Franz Benjamin Spingler, and Hubert A. Gasteiger. "The Manufacturing of Electrodes: Key Process for the Future Success of Lithium-Ion Batteries." Advanced Materials Research 1140 (August 2016): 304–11. http://dx.doi.org/10.4028/www.scientific.net/amr.1140.304.

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Lithium-ion batteries are a key technology for energy storage not only in consumer electronics but also in e-mobility and stationary applications. However, in order to guarantee the success of lithium-ion batteries in the long term, improvements related to performance, lifetime and production costs need to be made. Mastery of the highly interlinked process chain in lithium-ion battery manufacturing is a challenge and often acquired on the basis of experience. This paper illustrates the complexity of this process chain with a special focus on the roll-to-roll manufacturing of electrodes and discusses the application of a quality management system in lithium-ion battery production.

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Giorleo, Luca, Elisabetta Ceretti, and Claudio Giardini. "Speed Idle Roll Law Optimization in a Ring Rolling Process." Key Engineering Materials 651-653 (July 2015): 248–53. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.248.

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Ring Rolling is a complex hot forming process where different rolls are involved in the production of seamless rings characterized by extreme dimensions (i.e. external diameter higher more than 1m). Because each roll can be independently controlled from the other ones different speed laws must be set; usually, in the industrial environment, a milling curve is introduced to monitor the shape of the workpiece during the deformation in order to ensure a correct ring production. In former works the authors focused their attention on the influence of different milling curves for an industrial case and the results underlined that a ring produced with a good quality and lower loads and energy could be obtained imposing a linearly descending trend to the Idle roll speed law. However different approaches could be used in order to evaluate the mentioned speed law.In this work the authors enhanced the knowledge about the optimization of the Idle roll speed law: different Idle roll speed laws were designed and simulated and the results were compared in order to identify the best speed law that guarantees a good quality ring with lower loads and energy required for manufacturing.

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Nijman, Gerard. "A Fundamental Approach of the Cord Calendering Process." Rubber Chemistry and Technology 74, no. 4 (September 1, 2001): 715–28. http://dx.doi.org/10.5254/1.3544969.

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Abstract Calendering is one of the oldest rubber processing technologies. It is known that coating of fabrics has been done for almost 200 years. Steel cord and fabric cord topping is one of the processes in tire manufacturing. Specifications and tolerances for calendered cords are very tough. It is especially difficult to fulfill the thickness variation across the calendered ply and the cord density (end count). Modern calender lines are very complicated in order to fulfill these requirements. Despite that there is rather little research work done in the field of rubber calendering. The level of research was reduced when extruders started to become more common in the 1970s. The purpose of this paper is to present a calender model based on the flow in the nip of two rolls. The pressure build-up in the clearance explains the influence of roll deflection on geometrical parameters. It is also related to roll wear and therefore on long term consistency of the quality of calendered cord. Roll deflection compensating methods and their influence on quality are presented from the point of view of the presented model. Roll crowning specifications are explained and a discussion of why cord tension is needed to keep the end count constant is also given.

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Adeyemi, GJ, RS Dwyer-Joyce, C. Pinna, A. Hunter, JT Stephen, and A. Adebayo. "Non-intrusive measurement of strip thickness and roll-bite length in metal rolling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 10 (May 1, 2020): 1283–92. http://dx.doi.org/10.1177/0954405420915037.

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It is important to monitor the rolled strip thickness standard to minimize material waste and loss of profit due to strip flatness defects, and also to maintain the product’s size and dimensional homogeneity. Several online measurement techniques are available but none of this can give an in situ measurement within the roll bite. Due to this, a novice experimental method utilizing ultrasonic reflection sensor mounted on one roll was developed for in situ measurement of strip thickness and roll-bite length during cold rolling process. A pitch–catch method was used whereby a piezoelectric element generated an ultrasonic pulse and transmitted to the contact interface evaluated on a pilot mill. The reflected signal was captured by a second piezoelectric element and analysed to determine the condition at the strip–roll interface. This approach was implemented on a pilot mill and reflections from various locations in the roll bite during the rolling were recorded. Recorded signals were used to estimate the rolled strip thickness and roll-bite length after the rolling process.

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Huang, Guang Sheng, Ling Yun Wang, Zhong Wei Zhang, Guang Jie Huang, and Fu Sheng Pan. "Manufacturing Technique of Magnesium Alloy Sheets by Powder Rolling." Materials Science Forum 488-489 (July 2005): 445–48. http://dx.doi.org/10.4028/www.scientific.net/msf.488-489.445.

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Conventional manufacturing processes of metal and alloys sheets are rolling. The poor formability of magnesium alloys at room temperature makes rolling difficult. In the present paper, a manufacturing technique of sheets by powder rolling was employed to fabricate magnesium alloy sheets. The technique consisted of roll compaction, sintering, re-rolling and annealing. Powders of Mg-3 wt% Al mixed using a global mill were roll compacted into green sheets using two counter rotating rolls to the thickness of approximately 0.60 mm. Roll compacted green sheets were sintered at 823 K in argon atmosphere. Sintered green sheets were then re-rolled at ambient temperature to approximately 0.22 mm to obtain fully dense sheets. There was no significant edge cracking observed in the process of cold rolling. It is reasonable to believe that powder rolling is a promising technique for manufacturing magnesium alloys sheets.

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Jansson, E., A. Korhonen, M. Hietala, and T. Kololuoma. "Development of a full roll-to-roll manufacturing process of through-substrate vias with stretchable substrates enabling double-sided wearable electronics." International Journal of Advanced Manufacturing Technology 111, no. 11-12 (November 6, 2020): 3017–27. http://dx.doi.org/10.1007/s00170-020-06324-4.

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AbstractIn the recent years, there has been a growing interest towards printed stretchable electronics used in diagnostics, health-monitoring, and wearable applications. Double-sided electronic circuits with through-substrate vias offer a solution where the amount of printed circuitry and assembled SMDs (surface-mount devices) in direct contact with the human skin can be minimized. This improves not only the wearability and cost-effectiveness of the printed electronic devices but also the product safety and comfort to wear. Another factor decreasing the unit costs in printed electronics is the use of high volume, high speed, and continuous roll-to-roll (R2R) manufacturing processes. In this current paper, a full R2R process for the manufacturing of through-substrate vias on stretchable thermoplastic polyurethane (TPU) substrate was developed and verified. The through-substrate via-holes were manufactured in R2R using either laser-cutting or die-cutting. Rotary screen printing was used to print conductive tracks onto both sides of the stretchable substrate and to fill the via-holes. Eventually, conductive and stretchable through-substrate vias with low sheet resistance and low resistance deviation were reliably achieved with the developed process.

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Moon, C. H., and Y. Lee. "Methodology for draft schedule design of plate rolling process with peening effect considered." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 223, no. 9 (May 6, 2009): 1159–69. http://dx.doi.org/10.1243/09544054jem1417.

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We propose an approach for designing a draft schedule applicable to thick plate rolling. In the proposed approach, the peening effect, i.e. thick material is rolled with a small reduction ratio, is considered fully in computing roll force and torque. To determine an initial draft schedule, we calculate material thickness at each pass and total number of passes by taking the smallest of the critical reduction ratios (reduction ratio by maximum reduction increment, reduction ratio assigned in designing a plate mill, reduction ratios by allowable roll force and roll torque). To make a final draft schedule, we then propose two ways (thickness ratio correction (TRC) method and reduction ratio correction (RRC) method) that redistribute reduction ratios predetermined in the initial draft schedule. The proposed approach has been applied to POSCO No. 2 Plate Mill. Results reveal that the reduction ratios are determined by allowable roll torque if the material being rolled is relatively thick, but reduction ratios are decided by roll force as the material thickness being rolled decreases. It has been found that the thickness ratio correction method is useful when a heavy reduction ratio is necessary in the later part of the rough rolling sequence, and obtaining a uniform microstructure over material thickness during rolling is important. Meanwhile, the reduction ratio correction method is effective if surface defect generation on the material during rolling is a concern.

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Journal articles on the topic 'Roll-to-Roll Manufacturing Process'

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