Profile geometry-based controlled straigthening by partial rolling for inline correction of roll formed profiles

• Applicant: Professor Dr.-Ing. Peter Groche
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 537842522

Within the scope of the proposed transfer project, a novel, knowledge-based approach for straightening roll formed profiles by means of partial rolling is to be investigated and a control system for the straightening process is to be developed. Partial rolling aims to homogenize the inhomogeneous longitudinal strain distribution in the profile cross-section, which is the cause of profile defects, by selectively introducing additional longitudinal strains and thus straightening the profiles. The first part of the project focuses on investigating the effects occurring during straightening by means of partial rolling. With the aid of a straightener developed for partial rolling, the rolling forces required for the targeted introduction of longitudinal elongation into roll-formed profiles, the ratio of introduced elongation to width, the effects of partial rolling on the geometry of the profile cross-section and the surface properties, as well as the influence of the material properties in partial rolling are investigated. In the second part of the project, a control system for the straightening process will be developed and investigated. The control is based on the results of the investigations carried out and on an analytical model developed in the preceding DFG project which predicts the longitudinal strain distribution in the profile cross-section on the basis of the profile defects present. Based on the predicted longitudinal strain distribution, it is analyzed in which areas of the profile additional longitudinal strains have to be introduced. With the help of a model describing the relationship between the longitudinal strain to be introduced and the rolling force required for this, the manipulated variables for the actuators are specified, the profile is rolled locally and thus straightened. The procedure described aims to move from iterative and experience-based straightening to knowledge-based and controllable straightening, thus enabling sustainable production of roll formed profiles in the future.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Tillmann Profil GmbH