A Digital Twin-Based Study of Material Behavior in the Rolling Process

Year 2024, , 377 - 386, 31.12.2024

Kadir Gök , Cemal Esen

https://doi.org/10.34186/klujes.1578303

Abstract

The study proposes the development of a digital twin model for the rolling process. This virtual representation allows for the investigation of how various rolling parameters influence the quality of the final product. By employing finite element analysis (FEA), the model can simulate the rolling process under different conditions.

Specifically, the study focuses only workpiece material which includes aluminum alloy (Al2024) for digital twin scenario. Through simulations, critical parameters like the Z-force exerted on the workpiece can be determined and compared. This enables researchers to evaluate different scenarios and identify optimal rolling conditions without the need for costly physical experiments.

Keywords

Rolling, Friction coefficient, Roller Diameter, Finite Element Analysis

Haddelenme Sürecinde Malzeme Davranışının Dijital İkiz Temelli İncelenmesi

Abstract

Çalışma, haddeleme süreci için bir dijital ikiz modelinin geliştirilmesini önermektedir. Bu sanal temsil, çeşitli haddeleme parametrelerinin son ürünün kalitesini nasıl etkilediğini incelemeye olanak tanır. Sonlu elemanlar analizi (FEA) kullanılarak model, farklı koşullar altında haddeleme sürecini simüle edebilir.

Özellikle çalışma, dijital ikiz senaryosu için alüminyum alaşımı (Al2024) içeren yalnızca iş parçası malzemesine odaklanmaktadır. Simülasyonlar yoluyla, iş parçasına etki eden Z-kuvveti gibi kritik parametreler belirlenebilir ve karşılaştırılabilir. Bu, araştırmacıların farklı senaryoları değerlendirmelerine ve pahalı fiziksel deneylere gerek kalmadan optimum haddeleme koşullarını belirlemelerine olanak tanır.

Keywords

Haddeleme, sürtünme katsayısı, Hadde çapı, Sonlu elemanlar analizi

References

• Çapan, L. (2010). Metallere plastik şekil verme: Çağlayan Kitabevi.
• Esen, C. (2019). Optimization of rolling parameters by finite element analysis. (MsC Master Thesis). Manisa Celal Bayar Üniversitesi, Manisa.
• Gök, A., Inal, S., Taşpınar, F., Gülbandılar, E., & Gök, K. (2014). Fatigue behaviors of different materials for schanz screws in femoral fracture model using finite element analysis. Optoelectronics and Advanced Materials-Rapid Communications, 8(May-June 2014), 576-580.
• Gök, K. (2015). Development of three-dimensional finite element model to calculate the turning processing parameters in turning operations. Measurement, 75, 57-68. doi:https://doi.org/10.1016/j.measurement.2015.07.034
• Gök, K. (2021a). Investigation of the use of silicone pads to reduce the effects on the human face of classical face masks used to prevent from COVID-19 and other infections. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 235(5), 1742-1747. doi:10.1177/09544089211019581
• Gök, K. (2021b). Investigation Using Finite Element Analysis of Effect on Crater Geometry of Different Abrasive Types in Abrasive Water Jet Machining. Surface Review and Letters, 28(07), 2150060. doi:10.1142/s0218625x21500608
• Gök, K., & Gök, A. (2024). The Biomechanical Performance of Implant Screws with Different Biomaterials in Orthopedic Bone Fixation Procedures. Transactions of the Indian Institute of Metals. doi:10.1007/s12666-024-03371-3
• Gök, K., Gök, A., & Kişioğlu, Y. (2019a). Computer Aided Finite Element Simulation of the Developed Driller System for Bone Drilling Process in Orthopedic Surgery. Journal of Advanced Manufacturing Systems, 18(04), 583-594. doi:10.1142/s0219686719500318
• Gök, K., Inal, S., Urtekin, L., & Gök, A. (2019b). Biomechanical performance using finite element analysis of different screw materials in the parallel screw fixation of Salter–Harris Type 4 fractures. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 41(3), 143. doi:10.1007/s40430-019-1640-z
• Gök, K., Selçuk, A. B., & Gök, A. (2021). Computer-Aided Simulation Using Finite Element Analysis of Protect Against to Coronavirus (COVID-19) of Custom-Made New Mask Design. Transactions of the Indian Institute of Metals. doi:10.1007/s12666-021-02227-4
• Grieves, M. (2002). SME Management Forum Completing the Cycle: Using PLM Information in the Sales and Service Functions.
• Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems: John Wiley & Sons.
• Gunasekera, J. S., Jia, Z., Malas, J. C., & Rabelo, L. (1998). Development of a neural network model for a cold rolling process. Engineering Applications of Artificial Intelligence, 11(5), 597-603. doi:https://doi.org/10.1016/S0952-1976(98)00025-6
• Hu, Y., Zhang, Y., Ma, X., Du, X., Wang, W., & Zhang, H. (2024). Virtual commissioning and process parameter optimization of rolling mill based on digital twin. The International Journal of Advanced Manufacturing Technology, 130(1), 705-716. doi:10.1007/s00170-023-12718-x
• Kayalı, S. (1995). Plastik şekil verme ilke ve uygulamaları: problemleri ve çözümleri: Bilim Teknik ve Yayınevi.
• Liu, S., Lu, Y., Shen, X., & Bao, J. (2023). A digital thread-driven distributed collaboration mechanism between digital twin manufacturing units. Journal of Manufacturing Systems, 68, 145-159. doi:https://doi.org/10.1016/j.jmsy.2023.02.014
• Pirhan, Y., Gök, K., & Gök, A. (2020). Comparison of two different bowel anastomosis types using finite volume method. Computer Methods in Biomechanics and Biomedical Engineering, 23(8), 323-331. doi:10.1080/10255842.2020.1722809
• Ren, Y., Dong, J., He, J., Zhang, D., Wu, K., Xiong, Z., . . . Liu, S. (2024). A novel six-dimensional digital twin model for data management and its application in roll forming. Advanced Engineering Informatics, 61, 102555. doi:https://doi.org/10.1016/j.aei.2024.102555
• Sun, J., Chen, S., Ding, C., Peng, W., & Zhang, D. (2024). Application of digital twin for industrial process control: A case study of gauge-looper-tension optimized control in strip hot rolling [version 1; peer review: 1 not approved]. Digital Twin, 4(10). doi:10.12688/digitaltwin.17971.1
• Sun, T., He, X., & Li, Z. (2023). Digital twin in healthcare: Recent updates and challenges. Digit Health, 9(20552076221149651), Jan-Dec.