Asymmetrical Profile "Potshell" example notebook with DXF import and Lendl analysis

[sag-kalibreur]

Hi all, I created a notebook for an industrial application to calculate an asymmetrical profile (Potshell). In the notebook, the upper profile is created via a DXF import, the lower profile is a standard groove that is generated with PyRoll.

1. In the first step, the upper and lower profile halves are both calculated fully symmetrically. Marini's spread calculation is used for this analysis. The spreading behaviour of the fully symmetrical roll passes is examined. A flat pass is used as the second pass after the forming pass. At the end, the width, height and cross-sectional area of the two symmetrical profiles are averaged to obtain a good indication of the finished asymmetrical profile.

2. In the second step, both symmetrical pass sequences are divided into strips using the pillar model. Subsequently, the spread and fill level in the grooves are analysed according to A.E. Lendl.

Some notes

This is a slightly complicated asymmetrical flat profile. I noticed that the cross-section area calculation in the flat passes after the symmetrical pass sequences always outputs the complete rectangles instead of the real cross-section area.

The spread models from Sparling / Pawelski are very suitable for calculating the material flow in the grooves, but not for the complete width and height of the profile. Therefore, I calculated these in a further step using the Marini equation and also averaged them. In the end, the calculated profile matches the practical results very well.

Please take a look at the case with the cross section of the flat pass calculation and the different spreading results of the models of the overall profile and share your opinion on everything. I look forward to your feedback...

You can find the notebook here:
lendl-analysis-potshell-127-38.1.zip