مهندسی ساخت و تولید ایران

مهندسی ساخت و تولید ایران

تأثیر الگوی‌گل بر نیروی وارد بر غلتک‌ها در فرایند شکل‌دهی‌مجدد غلتکی سرد

نوع مقاله : مقاله پژوهشی

نویسندگان
1 دانشکده مهندسی مکانیک، دانشگاه تربیت مدرس، تهران، جمهوری اسلامی ایران
2 گروه مهندسی مکانیک، دانشگاه ایوانکی، ایوانکی، جمهوری اسلامی ایران
3 گروه مهندسی مکانیک، دانشگاه علم و فرهنگ، تهران، جمهوری اسلامی ایران
4 دانشکده فنی و مهندسی، دانشگاه اراک، اراک، جمهوری اسلامی ایران
5 دانشکده مهندسی مکانیک، دانشگاه صنایع و معادن ایران، تهران، جمهوری اسلامی ایران
چکیده
در این مقاله تأثیر طراحی الگوی‌گل بر نیروی وارد بر غلتک‌ها، در فرایند شکل‌دهی‌مجدد غلتکی سرد مورد بررسی قرار گرفته است. جهت بررسی این موضوع، ابتدا برای مقطع مستطیلی ۴۰ در۶۰ با ضخامت ۳ میلی‌متر چند الگوی‌گل طبق روش‌های رایج طراحی شده است. سپس این الگوها به همراه الگوی‌گل صنعتی این مقطع در نرم‌افزار آباکوس به‌صورت سه‌بعدی شبیه‌سازی و صحت نتایج شبیه‌سازی‌ها به کمک آزمایش عملی تأیید شده است. طبق نتایج شبیه‌سازی‌ها نشان داده ‌شد که مجموع کل نیروهای وارد بر غلتک‌ها در ایستگاه‌های مختلف تقریباً ثابت بوده و ارتباطی با شیوه‌ی طراحی الگوی‌گل ندارد. بر این اساس پیشنهاد شده است تا برای طراحی الگوی‌گل مناسب، ابتدا توسط یکی از روش‌های رایج الگوی‌گل طراحی شده و طبق آن کل نیروی وارد بر غلتک‌ها استخراج گردد. سپس الگوی‌گل جدید به‌گونه‌ای طراحی شود که نیروی وارد بر غلتک‌ها، در کل ایستگاه‌ها، توزیعی یکنواخت داشته باشد. بدین منظور معیاری جدید برای طراحی الگوی‌گل ارائه شده و بر اساس این معیار رابطه‌ای نوین برای ارتباط بین نیروی وارد بر غلتک‌ها با مقدار کاهش در هر ایستگاه برای این مقطع استخراج گردیده است. طبق این رابطه، الگوی‌گل جدیدی طراحی شده و کارایی این رابطه و الگوی‌گل جدید، با یکنواختی بهتر توزیع نیروی عمودی وارد بر غلتک‌ها نشان داده‌شده است. نتایج نشان می‌دهند به کمک این معیار می‌توان یکنواختی توزیع نیروی وارد بر غلتک‌ها را نسبت به شرایط صنعتی 5.6٪ بهبود بخشید.
کلیدواژه‌ها

عنوان مقاله English

The effect of the flower pattern on the applied force on the Rollers in the reshaping of cold roll forming process

نویسندگان English

Hosein Arzandeh 1
Mehdi Tajdari 2
Hassan Moslemi Naeini 1 3
Siamak Mazdak 4
Reza Alinejad 5
1 Department of Mechanical Engineering, Tarbiat Modares University, Tehran, IR Iran
2 Department of Mechanical Engineering, University of Eyvanekey, Eyvanekey, IR Iran
3 Department of Mechanical Engineering, Faculty of Engineering, University of Science and Culture, Tehran, IR Iran
4 Engineering Department, Arak University, Arak, IR Iran
5 Faculty of Mechanical Engineering, Iran University of Industries and Mines, Tehran, IR Iran
چکیده English

This paper investigates the effect of flower pattern design on the roll forces in reshaping cold roll forming. To examine this, several flower patterns were initially developed for a rectangular profile of 40x60 mm with a 3 mm thickness, following common design methods. Subsequently, these patterns, along with an industrial flower pattern for the same profile, were simulated in 3D using Abaqus software, with the accuracy of the simulations validated through experimental testing. The simulation results revealed that the total sum of forces exerted on the rolls remains relatively constant across various stations and is independent of the flower pattern method. Based on this finding, a design approach is proposed: initially, a flower pattern should be created using any common method, from which the total roll force is extracted. A new flower pattern should then be designed to achieve a more uniform distribution of the roll forces across all stations. For this purpose, a new criterion for flower pattern is introduced, and based on this criterion, a new relationship between the roll force and the reduction amount at each station for this profile is established. Following this relationship, a new flower pattern was developed, and the effectiveness of this approach and the new flower pattern was demonstrated through a better uniformity of the vertical roll force distribution. The results indicate that, using this criterion, the uniformity of the roll force distribution can be improved by 5.6% compared to industrial conditions.

کلیدواژه‌ها English

Reshaping of Cold Roll Forming
Flower Pattern Design
Force on the Rollers
Design Criterion
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