A hybrid flattening method for roller-leveling of flexible magnetic medium

Mechanics modeling of roller leveling process is presented in this work with aim placed on the manufacturing of flexible magnetic medium in linear magnetic encoders. Roller leveling process is a complex forming process that utilizes bending moments to achieve flattening of the process material. In the manufacturing of magnetic encoding medium, the release of residual stress is a crucial step since it is directly related to the mechanical flatness of the medium, which will significantly affect the performance of the magnetic encoder. In this paper, mechatronics integration of a roller leveler is developed for flattening of magnetic medium. A hybrid modeling of magnetic medium flattening method is established through analytical model to predict and analyze its residual curvature and stress with given design parameters. The relationship between leveling roller indentation and curvature of magnetic medium are investigated, followed by validation which is carried out using the proposed model, the magnetic medium and the roller leveler. The presented work can be implemented toward flattening and forming of common media.