Recent Development on Theory and Application of Variable Gauge Rolling, a Review

doi:10.1007/s40195-014-0065-z

Abstract

Abstract:

Variable gauge rolling (VGR) is a new technology for producing the materials which have the advantage of lightweight due to optimized thickness according to load distribution. The new progresses in the theoretical research and application of VGR are reviewed in this paper. Two basic equations, VGR-f and VGR-s, were deduced. The former is a new differential equation of force equilibrium, and the latter is a new form of formula for the law of mass conservation. Both of them provide a new base for the development of VGR analysis. As the examples of VGR’s application, tailor rolled blank (TRB) and longitudinal profile (LP) plate are introduced. Now TRBs are only produced in Germany and China, and have been used in the automotive manufacturing to play an important role in lightweight design. LP plates have been used in shipbuilding and bridge construction, and promised a bright prospect in reducing construction weight. In addition, new technologies and applications of VGR emerge constantly. Tailor welded strips and tailor rolled strips with variable thickness across the width can be used for progressive die and roll forming. The 3D profiled blank can be obtained by two-step rolling process. Tailor tubes with the variable wall thickness are an efficient way to reduce the weight. The blank with tailored thickness and mechanical property is also under development. Above products based on the tailored ideas provide a new materials-warehouse for the designers to select so as to meet the needs of weight reducing and material saving.

Key words: Variable gauge rolling, Tailor rolled blank, Longitudinal profile plate, Material saving, Weight reducing

Xianghua Liu, Qilin Zhao, Lizhong Liu. Recent Development on Theory and Application of Variable Gauge Rolling, a Review[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(3): 483-493.

Figures/Tables 19

Fig. 1 Three kinds of tailor products

Fig. 2 Sketch map of variable gauge rolling (1 backup roll, 2 work roll, 3 workpiece, 4 tracking device, 5 load sensor, 6 hydraulic cylinders, 7 thickness meter, 8 computer)

Fig. 3 Production and application of LP plates

Fig. 4 Schematic diagrams illustrate the production processing of TRB a and the periodical rolling of TRB b

Fig. 5 Three typical TRB products

Fig. 6 Three types of VGR process

Fig. 7 Mechanical analysis of upward rolling

Fig. 8 Rolling pressure in VGR rolling (K is the yield shear stress)

Fig. 9 Mass flow analysis of VGR process

Fig. 10 TRB sample by VGR experiment

Fig. 11 Monitored rolling force in VGR process

Fig. 12 Dimensions of the sample (in mm) and the uniaxial tension stress diagram of TRB sample with different displacements

Fig. 13 Cup drawing tests of TRB

Fig. 14 Industrial mill for the production of TRB based on the VGR technology

Fig. 15 Dimension of TRB a and the finished product CCB b

Fig. 16 Tailor welded strips or tailor welded coils

Fig. 17 Strip profile rolling a, widening of the groove b and tailor rolled strips c

Fig. 18 3D profiled blanks

Fig. 19 Tailor tubes: a tube with different thicknesses; b taper pipe; c lamp post

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