Preventing Core and Interlayer Buckling Defects in Wound Rolls During Manufacturing

在生产过程中，金属板材、纸张、聚合物和其他薄材料（称为“卷筒纸”）通常是在张力和高速下输送的。卷筒纸加工的阶段包括轧机减薄、分切、涂布、印刷和层压。这些材料被卷绕、运输，并以多吨大卷的形式储存。其生产的改进在很大程度上受到与精确移动和缠绕网而不引入重大缺陷有关的力学问题的限制。该研究项目的重点是减少与卷绕辊生产相关的应力引起的损伤。在不利应力存在的情况下，卷材及其缠绕的芯可能局部或全部发生屈曲。在最好的情况下，这样的缺陷会被消费者视为质量差的标志，在最坏的情况下，它们会要求整个卷都报废。失效模式描述了完全的机械不稳定性，通常被称为v型屈曲、凹陷坍塌、星状和辐状。一个预测模型正在开发的应力场在绕线辊，考虑现实的复杂效应，以前没有研究过。研究确定了制造工艺参数所起的作用，如张力、速度、辊宽、腹板和芯材性能、腹板材料表面粗糙度、芯材刚度以及心轴或芯盘设计。研究结果被用于指导工程解决方案的开发，以控制和提高卷绕辊在生产过程中的稳定性和质量。

Flat continuous strips of sheet metal, paper, polymers and other thin materials (referred to as "webs") are generally transported under tension and at high speed during production. Stages of web processing include thickness reduction in rolling mills, slitting, coating, printing, and laminating. These materials are wound onto, transported, and stored in the form of large multi-ton rolls. Improvements in their production are restricted to a large degree by mechanics problems associated with precisely moving and winding webs without introducing significant defects. This research project focuses on reducing the stress-induced damage associated with wound roll production. In the presence of unfavorable stresses, rolls of material and the cores onto which they are wound can buckle locally or entirely. At best, such defects are viewed by customers as a sign of poor quality, and at worst, they require the entire roll to be scrapped. Failure modes describe complete mechanical instability and are often termed V-buckling, sag collapse, starring, and spoking. A predictive model is being developed for the stress field within wound rolls which accounts for realistic complicating effects that have not previously been studied. The research identifies the roles played by such manufacturing process parameters as tension, speed, roll width, web and core material properties, surface roughness of the web material, core stiffness, and mandrel or core chuck design. The results are being used to guide the development of engineering solutions for controlling and improving the stability and quality of wound rolls during their production.