||In metalworking, rolling processes tend to induce non-uniform residual stress distributions in workpieces, resulting in various defects, such as edge waves and center buckles of the piece. Thus, tension leveling is commonly employed to correct these defects.|
The finite element method (FEM) can be employed to examine the performance levels of tension-leveling processes. However, developing an FEM model is extremely time-consuming because deformation types may vary, and all residual stress elements of the defective workpiece after rolling must be individually input into the model. Therefore, the present study involves designing a program that rapidly models defective sheet metal workpieces, facilitating finite element analysis and substantially reducing modeling times when FEM is employed to simulate the performance levels of tension leveling processes of defective workpieces after rolling.
Using Marc, a finite element analysis solution, and the C programming language, an automated modeling program was developed to construct finite element 3D models of the tension-leveling processes used to treat workpieces that exhibit edge wave and center buckles after rolling. Users simply input relevant data, such as material parameters, sheet specification, wave type, wave quantity, wave size, wave position, residual stress distribution following the rolling process, and tensility, into the Q&A interface and the program automatically generates a finite element model.
The proposed automated modeling program reduces modeling times by more than 95%, presenting a simple data input interface that easily and automatically generates models regardless of the complexity of the defects or distributions.
In summary, numerous model simulations were successfully completed using the proposed program. Combined with the Taguchi method, the proposed program can be used to observe workpieces that demonstrated asymmetrical edge wave defects, demonstrating how variations in relative wave-workpiece sizes and the tensile variations affected the removal rate of residual stress.