Preventing Core and Interlayer Buckling Defects in Wound Rolls During Manufacturing

金属板、纸、聚合物和其它薄材料的平坦连续条带（称为“幅材”）通常在生产期间在张力下以高速输送。 卷材加工的阶段包括在辊米尔斯中的厚度减小、纵切、涂布、印刷和层压。 这些材料以大型多吨卷的形式缠绕、运输和储存。 它们的生产的改进在很大程度上受到与精确移动和卷绕幅材而不引入显著缺陷相关的机械问题的限制。 该研究项目的重点是减少与卷筒生产相关的应力引起的损坏。 在存在不利应力的情况下，材料卷和它们缠绕在其上的芯可以局部或全部弯曲。 在最好的情况下，这种缺陷被客户视为质量差的标志，在最坏的情况下，它们需要整个卷报废。 失效模式描述了完全的机械不稳定性，通常称为V形屈曲、凹陷塌陷、星状和轮辐状。 一个预测模型正在开发的应力场内的卷绕辊，占现实的复杂的影响，以前没有被研究。 该研究确定了所发挥的作用，如张力，速度，辊宽，网络和芯材料的性能，网络材料的表面粗糙度，芯刚度，芯轴或芯卡盘设计等制造工艺参数。 研究结果被用于指导工程解决方案的开发，以控制和提高生产过程中卷取辊的稳定性和质量。

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.