A new method of intelligent control for system stabilization in process-integrated powder coating by radial axial rolling of rings

Process-integrated powder coating by radial axial rolling of rings represents a novel hybrid production process to apply powder metallurgical coatings on large ring-shaped parts. The goal is to noticeably improve resistance against abrasive wear. To investigate important quantities such as e.g. the residual porosity in the layer and the stress states in the rolling zone, the versatile use of the finite element method (FEM) is crucial. Therefore, a parameterized FE model is developed on the basis of a finite strain viscoplastic material formulation. Reasonably controlling the movement of the guide rollers is an important task. It will be shown that the development of a mathematical formulation for the analytical design of such a control system based on Apollonian mutually orthogonal circles is necessary. The paper will be concluded by simulation results of the ring rolling process and comparisons with experimental results.