The influence of residual stress on a roll forming process

Roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for structural components. Because of the large variety of applications of roll forming in the industry, Finite Element Analysis (FEA) is increasingly utilized for roll forming process design. Bending is the dominant deformation mode in roll forming and sheet materials used in the process are often temper rolled (skin passed), roller- or tension-levelled. These processes introduce residual stresses into the material, and recent studies have shown that those affect the material behaviour in bending. A thickness reduction rolling process available at Deakin that leads to material deformation similar to an industrial temper rolling operation was used in this study to introduce residual stresses into a dual phase, DP780, steel strip. The initial and thickness reduced strips were then used in a 5-stand experimental V-section roll forming set-up to identify the effect of residual stress on the final shape. The influence of residual stress and the effect of plastic deformation on the material behaviour in roll forming are separately determined in numerical simulation. The results show that the thickness reduction rolling process decreases the maximum bow height while the springback angle and end flare increase. Comparison with experimental results shows that using material data from the conventional tensile test in a numerical simulation does not allow for the accurate prediction of shape defects in a roll forming process if a residual stress profile exists in the material. On the other hand including the residual stress information leads to improved model accuracy.

Asymmetric rolling of 5182 aluminium alloy and interstitial free steel sheets

This Ph.D. research focuses on asymmetric rolling (ASR), as an alternative method for improving mechanical responses of aluminium-magnesium alloy and interstitial free (IF) steel regarding industrial requirements. Aluminium alloys are attractive materials in various industries due to their appropriate properties such as low density and corrosion resistance; however, their low formability has limited their applications. As formability of aluminium alloys can be improved through texture development, part of this dissertation is dedicated to producing the desired crystallographic texture with the ASR process. Two types of ASR (i.e. reverse and continuous asymmetric rolling) were investigated. The impact of shear deformation imposed by ASR processes on developing the desirable texture and consequently on mechanical behaviours was observed. The developed shear texture increased the normal and also planar anisotropy. Texture evolution during plastic deformation as well as induced mechanical behaviour were simulated using the “self-consistent” and Taylor models. Interstitial free (IF) steel was the second material selected in this dissertation. Since IF steel is one of the most often used materials in automotive industries it was chosen to investigate the effect of shear deformation through ASR on its properties. Two types of reverse and continuous asymmetric rolling were carried out to deform IF steel sheets. The results of optical microscopy and atomic force microscopy observations showed no significant difference between the grains’ morphology of asymmetric and conventionally rolled samples, whereas the obtained results of transmission electron microscopy indicated that fine and equiaxed dislocation cells were formed through the asymmetric rolling process. This structure is due to imposed shear deformation during the ASR process. Furthermore, the mechanical behaviour of deformed and annealed sheets was evaluated through uniaxial tensile tests. Results showed that at low thickness reductions (18%) the asymmetric rolled sample presented higher stress than that of the conventionally rolled sheet; while for higher thickness reductions (60%) the trend was reversed. The texture analyses indicated that intense rolling texture components which developed through 60% thickness reduction of conventional rolling cause a relatively higher stress; on the contrary the fine structure resulting from ASR appears to be the source of higher stress observed after pre-deformation of 18%.

Eccentricity and hardness control in cold rolling mills with a dynamically constructed neural controller

The main objective of a steel strip rolling process is to produce high quality steel at a desired thickness.  Thickness reduction is the result of the speed difference between the incoming and the outgoing steel strip and the application of the large normal forces via the backup and the work rolls.  Gauge control of a cold rolled steel strip is achieved using the gaugemeter principle that works adequately for the input gauge changes and the strip hardness changes.  However, the compensation of some factors is problematic, for example, eccentricity of the backup rolls.  This cyclic eccentricity effect causes a gauge deviation, but more importantly, a signal is passed to the gap position control so to increase the eccentricity deviation.  Consequently, the required high product tolerances are severely limited by the presence of the roll eccentricity effects.
In this paper a direct model reference adaptive control (MRAC) scheme with dynamically constructed neural controller was used.  The aim here is to find the simplest controller structure capable of achieving an optimal performance.  The stability of the adaptive neural control scheme (i.e. the requirement of persistency of excitation and bounded learning rates) is addressed by using as the inputs to the reference model the plant's state variables.  In such a case, excitation is due to actual plant signals (states) affected by plant disturbances and noise.  In addition, a reference model in the form of a filter with a desired transfer function using Modulus Optimum design was used to ensure variance in the desired dynamic characteristics of the system.  The gradually decreasing learning rate employed by the neural controller in this paper is aimed at eliminating controller instability resulting from over-aggressive control.  The moving target problem (i.e. the difficulty of global neural networks to perfrom several separate computational tasks in closed -loop control) is addressed by the localized architecture of the controller.  The above control scheme and learning algorithm offers a method for automatic discovery of an efficient controller.
The resulting neural controller produces an excellent disturbance rejection in both cases of eccentricity and hardness disturbances, reducing the gauge deviation due to eccentricity disturbance from 33.36% to 4.57% on average, and the gauge deviation due to hardness disturbance from 12.59% to 2.08%.

Short-range order kinetics in alpha-AgZn for various states of post-deformation defect annealing after cold-rolling

Kinetics of short-range ordering (SRO) in Ag with 21, 23 and 28 at% Zn is investigated by residual resistometry during isochronal and isothermal heat treatment for different states of post-deformation defect annealing after cold-rolling to about 30 and 60% thickness reduction. Resistivity changes due to pure ordering can be separated from the as-measured total resistivity change which includes defect annealing. Although the initial state of SRO of the as-rolled material can be estimated to be comparably low, for as-rolled and partially annealed states by appropriate thermal treatment evolution of SRO is achieved which corresponds quite well to that of recrystallized samples. It is observed, however, that quenched-in surplus vacancies contribute considerably to the ordering process for the recrystallized state and that this contribution is still increased by the grain growth during the final stage of annealing. It therefore turns out that SRO-kinetics under equilibrium vacancy conditions can be better observed in a state of post-deformation annealing, for which deformation induced point defects are annealed-out, but a relatively high dislocation density is still present to act as a vacancy sink. Copyright (C) 1996 Acta Metallurgica Inc.

Changes of microstructure in alpha AgZn during post-deformation annealing after cold-rolling

The annealing processes of deformation-induced defects after cold-rolling to about 30 and 60% thickness reduction were investigated for Ag-21, 23, 28 at% Zn by means of residual electrical resistivity, microhardness, light microscopy and transmission electron microscopy (TEM) Three annealing stages have been detected and consistently interpreted as annealing-out of mainly point defects and their agglomerates (stage I), formation of dislocation cells and recrystallized strain-free grains (stage II) and grain growth (stage III). Further, it is tried to determine the evolution of defect production (point defects and dislocations) during rolling deformation from measured changes of electrical resistivity and microhardness. Copyright (C) 1996 Acta Metallurgica Inc.

Symmetric and asymmetric rolling of low carbon steels

 In this study, it is shown that a close to ideal shear texture can be formed throughout the thickness of a rolled sheet. Such rotation of rolling texture not only leads to the enhancement in grain refinement but also the secondary processing as compared to the symmetric rolling.

Undersökning av steady state och utvärdering av valskraft och friktion vid kallvalsning av aluminium

The purpose with this thesis was to examine the cold rolling mill located at Högskolan Dalarna and to stabilize the rolling process, to achieve steady state. Experiments with cold rolling of an aluminium strip have given results for rolling force, friction, reduction, strip tension and strain hardening. Results show that steady state has been found for the experiments with roll force and strain hardening, and not been found for the experiments with friction and reduction. Results show that increased strip tension gives lower roll forces. The roll force equation of Stone shows comparable results with reality for dry contact with reductions up to 30 %, but starts being incomparable with higher reductions. The roll force equation of Stone shows a bit higher roll forces than reality gave, but was comparable within reductions from 13 to 50 %. Experiments have shown that the aluminium strip has gone through strain hardening. Experiments show how the set roll gap did not yield the desired thickness reduction, there for the elastic spring constant for the rolling mill was examined and determined to be 417 N / mm for the specific alloy band. The influence of tension strip for roll force was examined and Results confirm the theory about how the roll force is decreased by increasing tension strip. The work rolls started to slip against the alumina strip as high tension strip; 70 N/mm2, gave low roll force; < 15kN.

Prediction of stress-strain behaviors in steels using an integrated constitutive, FEM and ANN model

Austenitic steels with a carbon content of 0.0037 to 0.79 wt% C are torsion tested and modeled using a physically based constitutive model and an Integrated Phenomenological and Artificial neural Network (IPANN) model. The prediction of both the constitutive and IPANN models on steel 0.017 wt% C is then evaluated using a finite element (FEM) code ABAQUS with different reduction in the thickness after rolling through one roll stand. It is found that during the rolling process, the prediction accuracy of the reaction force from FEM simulation for both constitutive and IPANN models depends on the strain achieved (average reduction in thickness). By integrating FEM into IPANN model and introducing the product of strain and stress as an input of the ANN model, the accuracy of this integrated FEM and IPANN model is higher than either the constitutive or IPANN model.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Comparative analysis of three rotary instruments used for coronal pre-enlargement in radicular dentin thickness and root canal area of mandibular molars

Purpose: The purpose of this study was to evaluate the increase of the cervical area and dentin thickness in mesial and distal walls of the mesial canals from mandibular molars after the use of LA Axxess (LA), CP Drill (CP) and Gates-Glidden (GG) rotary instruments. Material and Methods: Sixty root canals from thirty mandibular first molar were sectioned 3 mm below the cement-enamel junction, divided in 3 groups (n = 20 root canals, each) according to rotary instrument used, and the cervical images were captured before and after pre-enlargement instrumentation. The increase of the instrumented cervical area (mm2) and the dentin removal thickness (mm), at mesial and distal walls were calculated using Image tools software, by comparison of images. Data were analyzed by ANOVA and Tukey tests (p=0.05). Results: All rotary instruments promoted thickness reduction in dentin walls. In mesial wall, all rotary instruments promoted similar thickness reduction of dentinal wall and did not differ from each other (p>0.05). In distal wall, LA Axxess instrument promoted higher dentin thickness reduction than other groups (p<0.05). The three rotary instruments promoted different increase at the instrumented cervical area (p<0.05), LA promoted the highest increase area and GG and CP presented similar results. Conclusion: LA 20/0.06 promoted the highest thickness reduction in distal wall and increase of cervical area of root canal. On the other hand, CP was the safest instrument, with lower dentin removal of distal wall and similar increased area to GG.

Exploring retinal markers of diabetic neuropathy

Purpose To investigate the application of retinal nerve fibre layer (RNFL) thickness as a marker for severity of diabetic peripheral neuropathy (DPN) in people with Type 2 diabetes. Methods This was a cross-sectional study whereby 61 participants (mean age 61 [41-75 years], mean duration of diabetes 14 [1-40 years], 70% male) with Type 2 diabetes and DPN underwent optical coherence tomography (OCT) scans. Global and 4 quadrant (TSNI) RNFL thicknesses were measured at 3.45mm around the optic nerve head of one eye. Neuropathy disability score (NDS) was used to assess the severity of DPN on a 0 to 10 scale. Participants were divided into three age-matched groups representing mild (NDS=3-5), moderate (NDS=6-8) and severe (NDS=9-10) neuropathy. Two regression models were fitted for statistical analysis: 1) NDS scores as co-variate for global and quadrant RNFL thicknesses, 2) NDS groups as a factor for global RNFL thickness only. Results Mean (SD) RNFL thickness (µm) was 103(9) for mild neuropathy (n=34), 101(10) for moderate neuropathy (n=16) and 95(13) in the group with severe neuropathy (n=11). Global RNFL thickness and NDS scores were statistically significantly related (b=-1.20, p=0.048). When neuropathy was assessed across groups, a trend of thinner mean RNFL thickness was observed with increasing severity of neuropathy; however, this result was not statistically significant (F=2.86, p=0.065). TSNI quadrant analysis showed that mean RNFL thickness reduction in the inferior quadrant was 2.55 µm per 1 unit increase in NDS score (p=0.005). However, the regression coefficients were not statistically significant for RNFL thickness in the superior (b=-1.0, p=0.271), temporal (b=-0.90, p=0.238) and nasal (b=-0.99, p=0.205) quadrants. Conclusions RNFL thickness was reduced with increasing severity of DPN and the effect was most evident in the inferior quadrant. Measuring RNFL thickness using OCT may prove to be a useful, non-invasive technique for identifying severity of DPN and may also provide additional insight into common mechanisms for peripheral neuropathy and RNFL damage.

Thinning vertical graphenes, tuning electrical response : from semiconducting to metallic

A simple, uniquely plasma-enabled and environment-friendly process to reduce the thickness of vertically standing graphenes to only 4–5 graphene layers and arranging them in dense, ultra-large surface area, ultra-open-edge-length, self-organized and interconnected networks is demonstrated. The approach for the ultimate thickness reduction to 1–2 graphene layers is also proposed. The vertical graphene networks are optically transparent and show tunable electric properties from semiconducting to semi-metallic and metallic at room and near-room temperature, thus recovering semi-metallic properties of a single-layer graphene.

Exploring Retinal Markers of Diabetic Neuropathy

Purpose : To investigate the application of retinal nerve fibre layer (RNFL) thickness as a marker for severity of diabetic peripheral neuropathy (DPN) in people with Type 2 diabetes. Methods : This was a cross-sectional study whereby 61 participants (mean age 61 [41-75 years], mean duration of diabetes 14 [1-40 years], 70% male) with Type 2 diabetes and DPN underwent optical coherence tomography (OCT) scans. Global and 4 quadrant (TSNI) RNFL thicknesses were measured at 3.45mm around the optic nerve head of one eye. Neuropathy disability score (NDS) was used to assess the severity of DPN on a 0 to 10 scale. Participants were divided into three age-matched groups representing mild (NDS=3-5), moderate (NDS=6-8) and severe (NDS=9-10) neuropathy. Two regression models were fitted for statistical analysis: 1) NDS scores as co-variate for global and quadrant RNFL thicknesses, 2) NDS groups as a factor for global RNFL thickness only. Results : Mean (SD) RNFL thickness (µm) was 103(9) for mild neuropathy (n=34), 101(10) for moderate neuropathy (n=16) and 95(13) in the group with severe neuropathy (n=11). Global RNFL thickness and NDS scores were statistically significantly related (b=-1.20, p=0.048). When neuropathy was assessed across groups, a trend of thinner mean RNFL thickness was observed with increasing severity of neuropathy; however, this result was not statistically significant (F=2.86, p=0.065). TSNI quadrant analysis showed that mean RNFL thickness reduction in the inferior quadrant was 2.55 µm per 1 unit increase in NDS score (p=0.005). However, the regression coefficients were not statistically significant for RNFL thickness in the superior (b=-1.0, p=0.271), temporal (b=-0.90, p=0.238) and nasal (b=-0.99, p=0.205) quadrants. Conclusions : RNFL thickness was reduced with increasing severity of DPN and the effect was most evident in the inferior quadrant. Measuring RNFL thickness using OCT may prove to be a useful, non-invasive technique for identifying severity of DPN and may also provide additional insight into common mechanisms for peripheral neuropathy and RNFL damage.

Effect of different surface profile on wear of rail steel (AS1085.1) used in Australian heavy-haul railways

The extreme diversity of conditions acting on railways necessitates a variety of experimental approaches to study the critical wear mechanisms that present themselves at the contact interface. This work investigates the effects of contact pressure and geometry in rolling-contact wear tests by using discs with different radii of curvature to simulate the varying contact conditions that may be typically found in the field. It is commonly adapted to line contact interface as it has constant contact pressure. But practical scenario of the rail wheel interface, the contact area increase and contact pressure change as tracks worn off. The tests were conducted without any significant amount of traction, but micro slip was still observed due to contact deformation. Moreover, variation of contact pressure was observed due to contact patch elongation and diameter reduction. Rolling contact fatigue, adhesive and sliding wear were observed on the curved contact interface. The development of different wear regimes and material removal phenomena were analysed using microscopic images in order to broaden the understanding of the wear mechanisms occurring in the rail-wheel contact.

Experimental investigation of wear modes of hardened rail material used in Australian heavy-haul railways

This work investigates the effects of contact pressure and geometry in rolling-contact wear tests by using discs with different radii of curvature to simulate the varying contact conditions that may be typically found in the field. The tests were conducted without any significant amount of traction, but micro slip was still observed due to contact deformation. Moreover, variation of contact pressure was observed due to contact patch elongation and diameter reduction. Rolling contact fatigue, adhesive and sliding wear were observed on the curved contact interface. The development of different wear regimes and material removal phenomena were analyzed using microscopic images in order to broaden the understanding of the wear mechanisms occurring in the rail-wheel contact.