Development of a free-surface profile prediction model for multi-pass shape roll die drawing process using response surface method
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초록
In the multi-pass shape drawing process used for metal forming, the drawing force is typically applied unevenly to the material, thus causing errors in the dimensions of the material. In addition, the process is time consuming and costly. To overcome these problems, the roll die drawing process replaces the fixed drawing dies with non-driven roll dies that can undergo rotational movements to reduce friction forces at the die-material contact point. In this study, we propose a free-surface profile prediction model using the response surface method for the roll gap of a multi-pass drawing process using a roll die to fabricate square drawing material. We first derived geometrical parameters to apply to the response surface method. Then, using four process parameters that influence the deformation behavior of the material, a Box-Behnken design for response surface analysis was proposed, and a secondorder regression model was derived through finite element analyses. In addition, finite element analysis was performed to validate the free-surface profile prediction model. Our verification results confirmed that the free-surface profiles predicted by the theoretical model agreed with those obtained via finite element analysis. Hence, our proposed free-surface profile prediction model based on response surface analysis can be used to design rectangular-shaped roll die drawing processes.
Abstract
In the multi-pass shape drawing process used for metal forming, the drawing force is typically applied unevenly to the material, thus causing errors in the dimensions of the material. In addition, the process is time consuming and costly. To overcome these problems, the roll die drawing process replaces the fixed drawing dies with non-driven roll dies that can undergo rotational movements to reduce friction forces at the die-material contact point. In this study, we propose a free-surface profile prediction model using the response surface method for the roll gap of a multi-pass drawing process using a roll die to fabricate square drawing material. We first derived geometrical parameters to apply to the response surface method. Then, using four process parameters that influence the deformation behavior of the material, a Box-Behnken design for response surface analysis was proposed, and a secondorder regression model was derived through finite element analyses. In addition, finite element analysis was performed to validate the free-surface profile prediction model. Our verification results confirmed that the free-surface profiles predicted by the theoretical model agreed with those obtained via finite element analysis. Hence, our proposed free-surface profile prediction model based on response surface analysis can be used to design rectangular-shaped roll die drawing processes.
참고문헌 (14)
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