Dynamic FE Analysis for Reducing the Flat Areas of Formed Shapes Obtained by Roll Bending Process

2013 ◽  
Author(s):  
Hoang Quan Tran ◽  
Henri Champliaud ◽  
Zhengkun Feng ◽  
Thien-My Dao
Keyword(s):  
Rolling Direction ◽  
Vertical Displacement ◽  
Fe Model ◽  
Forming Process ◽  
Dynamic Simulations ◽  
Continuous Forming ◽  
Flat Area ◽  
Roll Bending ◽  
Bending Process ◽  
Bottom Roll

Roll bending is a continuous forming process where plates, sheets, beams, pipes, and even rolled shapes and extrusions are bent to a desired curvature using forming rolls. Over the years, with the advantages such as reducing setting up time, the cost in tooling investment and equipment, the roll bending process was fundamental for manufacturing cylindrical shapes. However, the process always leaves a flat area along the leading and trailing edges of the workpiece. Therefore, accuracy could be a challenge when the part to be produced is large and made of high strength steel. There are several methods to minimize the flat area. Among them, for the asymmetrical configuration, moving slightly the bottom roll along the rolling direction may have the highest effect. On the other hand local adjustment of the bottom roll location is also important for providing the pressure needed for gripping and carrying the workpiece through the rolls. Then by optimizing the vertical displacement of the bottom roll one can minimize the span of flat areas. The main objective of this research is to assess 3D dynamic Finite Element (FE) model with Ansys/LS-Dyna for the simulation and analysis of the deformation of the workpiece during the manufacturing of cylindrical parts. Various dynamic simulations based on 3D element are performed to provide better understanding of the whole deformation history and to establish the relationship between the location of the bottom roll and the end shapes of the formed cylinders. The results from FE simulations are then compared with corresponding experimental results from an industrial roll bending machine in order to improve the quality of the final shape.

Investigations on Three-Roll Bending of Plain Tubular Components

2009 ◽  
Vol 410-411 ◽  
pp. 325-334 ◽  
Author(s):  
Marion Merklein ◽  
Hinnerk Hagenah ◽  
Massimo Cojutti
Keyword(s):  
Material Behavior ◽  
Fe Model ◽  
Forming Process ◽  
Widespread Application ◽  
Numerical Investigations ◽  
Industrial Sectors ◽  
Roll Bending ◽  
First Results ◽  
Bending Radius ◽  
High Flexibility

Bent metal tubes find a widespread application in many industrial sectors. Among different bending processes developed for the manufacturing of these components, three-roll bending is characterized by a high flexibility, as only one toolkit per tube diameter is necessary to form the required bending radius. In this type of forming process the part geometry is obtained by means of a relative movement of the die (setting roll) towards the fixed tools (bending and holding roll) with simultaneous feeding of the tube. This study describes the FE-model developed for the three-roll bending and presents first results of numerical investigations conducted on steel tubes made of carbon steel St37. By the FE-analysis great attention is paid on the modeling of the stiffness of the tool, on the description of the kinematics of the setting roll as well as on the characterization of the material behavior for the simulation. The results of the numerical investigations are compared with experiments conducted with a CNC-bending machine available at the Chair of Manufacturing Technology of the University of Erlangen. As a main criterion for the validation of the FE-model the radius of the tube at the extrados and the bending angle are chosen. The geometry of the part is measured by means of both optical and tactile measuring devices.

FEM-Based Simulation and Gripper Jaw Trajectory Fitting of Stretch-Bending Process for a Bending Beam of Railway Vehicles

2013 ◽  
Vol 372 ◽  
pp. 661-665
Author(s):  
Sheng Man Wang ◽  
Xin Hua Yang ◽  
Xing Lu
Keyword(s):  
Control Method ◽  
Die Design ◽  
Railway Vehicle ◽  
Fe Model ◽  
The Finite Element Method ◽  
Forming Process ◽  
Stretch Bending ◽  
Bending Process ◽  
Design Requirements ◽  
Displacement Control Method

The bending beam of railway vehicle is made of thin stainless steel, with large sizes and unsymmetrical section, and prone to defects during stretch-bending forming process, such as wrinkling, cross-section distortion and so on. A reasonable trajectory of gripper jaws could make for mitigating the mentioned defects. The Finite Element Method was employed to fit the trajectory as well as simulate the forming process. The FE model was built by using the commercial FE software Hypermesh and ABAQUS/CAE. The analysis was carried out based on dynamic explicit and displacement control method. On this basis, the actual stretch bending process was developed according to the fitted trajectory and simulated process. The actual production process indicates that the formed beam can meet the design requirements, and the method is feasible and economical, as well as can contribute to a better understanding of stretch bending process and die design.

Research on Bending Process of Integral Panel Skins

2011 ◽  
Vol 299-300 ◽  
pp. 1048-1051
Author(s):  
Jin Song Liu ◽  
Ying Guo ◽  
Shi Hong Zhang ◽  
Han Xiao
Keyword(s):  
Finite Element Method ◽  
Simple Structure ◽  
Incremental Forming ◽  
Aerospace Industry ◽  
Light Weight ◽  
The Finite Element Method ◽  
Forming Process ◽  
Roll Bending ◽  
Bending Process ◽  
High Structure

With the advantages such as light weight, high structure intensity and good rigidity, integral panel skins have been widely applied in aerospace industry. The forming process of mechanical milling-filling auxiliary roll bending and the incremental bending of integral panel skins were proposed based on the finite element method and the experiments technique. The research shows that the shapes of panel skins were binded by the ribs plastic deformation. The roll bending was suitable to the panel skins with the low ribs or the simple structure. The incremental forming was suitable to the panel skins with the high ribs or the involutes structure.

scholarly journals Numerical Modelling of the Three-Roll Bending Process of a Thin Plate

2020 ◽  
Vol 13 (1) ◽  
pp. 133-136
Author(s):  
Péter Máté ◽  
András Szekrényes
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Numerical Method ◽  
Simple Procedure ◽  
Rolling Direction ◽  
Curvature Function ◽  
The Finite Element Method ◽  
Roll Bending ◽  
Bending Process ◽  
Element Method

AbstractThe three-roll bending process is a simple procedure, commonly used in the industry, through which a cylindrical surface can be produced from a sheet plate. This process is mainly controlled through experience and it is described with the finite element method, except for a very few numerical and analytical investigations. The topic of this article is to present a numerical method, through which the curvature function along the rolling direction can be calculated. This article presents the proposed numerical method and its verification with the finite element method. The results of the two numerical methods are in good agreement.

Influences of Final Pipe Forming Process by Roll Bending Method on the Mechanical Properties of SAW Pipes

2010 ◽  
Author(s):  
Afshin Zandipoor ◽  
Reza Shamloo
Keyword(s):  
Mechanical Properties ◽  
Forming Process ◽  
Final Shape ◽  
Roll Bending ◽  
Bending Process ◽  
Pipe Mill

There are three main methods and process for forming pipes from plates “Roll Bending”, “JCOE” and “UOE”. In all of the above mentioned ways part of the pipe will remain flat, and can not achieve the desired curvature of the pipe. These areas are generally at the two longitudinal edges of the open seam pipes. For obviation of these flat areas at the longitudinal edges of the pipe, the pre forming machines for “JCOE” and “UOE” processes, and the post bending machine for “the Roll Bending” process are used. In the post bending machine the final shape of the pipes is determined based on the rate of the machine hoist pressure and the spaces between the rolling dies. These parameters can have various effects on the mechanical properties of the final welded pipes. In the research that has been conducted at SAFA Rolling & Pipe Mill Company, the amount of hoist pressure and the final shape of the open seam pipes in the post bending machine, and their influences on the mechanical properties of the welded pipes, have been investigated herein.

Kinematics-Based Determination of the Rolling Region in Roll Bending for Smoothly Curved Plates

2000 ◽  
Vol 123 (2) ◽  
pp. 284-290 ◽  
Author(s):  
Jong Gye Shin ◽  
Joon Tae Park ◽  
Hyunjune Yim
Keyword(s):  
Regression Analysis ◽  
Linear Regression ◽  
Systematic Approach ◽  
Linear Regression Analysis ◽  
Forming Process ◽  
Roll Bending ◽  
Bending Process ◽  
Curvature Distribution ◽  
Good Agreement

This paper proposes and develops a kinematics-based, systematic approach to determine the region of a plate to be rolled, in order to fabricate smoothly curved plates. The approach includes a kinematic analysis to calculate the plate’s curvature distribution, and, in addition, a linear regression analysis to determine the initial and final locations of the roller during the roll bending process. Three artificial cases and two real cases have been studied, and the results are in good agreement with field practices. This approach will play an important role in the automation and optimization of the plate forming process.

Experimental and Numerical Examination on Formability and Microstructure of AA3003-H18 Alloy in Single Point Incremental Forming Process

2021 ◽  
Vol 904 ◽  
pp. 14-19
Author(s):  
Mohanraj Murugesan ◽  
Krishna Singh Bhandari ◽  
Jae Hag Hahn ◽  
Dong Won Jung
Keyword(s):  
Tensile Test ◽  
Material Properties ◽  
Computer Aided Design ◽  
Incremental Forming ◽  
Single Point ◽  
Rolling Direction ◽  
Fe Model ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Computer Aided

The single-point incremental forming process has witnessed significant advantages in automobiles, aerospace, and medical applications in recent years because of its flexibility in manufacturing complex shapes. In detail, the components are produced only using the toolpath, which is guided by computer-aided manufacturing software. However, during the forming process, the parts might experience fractures, which could heavily impact the formed part's geometric accuracy. The main purpose of this study is to analyze the formability of an AA3003-H18 aluminum alloy material in the SPIF process; for this purpose, the material properties are extracted from the experimental simple tensile test in three directions corresponding to the material rolling direction. At first, a simple tensile test is modeled and estimated the material properties for conducting the numerical simulations. Second, the real-time experiments of the SPIF process in terms of predefined forming conditions are performed, and then the surface roughness was measured to check the surface quality of the formed parts. Then, the formed parts are scanned using a 3D ATOS scanner and compared against the desired computer-aided design (CAD) model. Eventually, the numerical results are discussed in comparison with the experimental outcome and displayed a significant correlation toward the expected results. This results comparison communicates that the introduced finite element (FE) model can be adopted for investigating the appearance of thinning location, thinning reduction, distributions of stress and strain. The overall results show that satisfying material formability in better surface finish and geometric dimensional accuracy can be accomplished when the forming conditions are designed appropriately.

Experimental study on the cross-shear roll bending process

2021 ◽  
Author(s):  
Mengrou Lv ◽  
Lianhong Zhang ◽  
Baiyan He ◽  
Feiping Zhao ◽  
Senlin Li ◽  
...  
Keyword(s):  
Experimental Study ◽  
Roll Bending ◽  
Bending Process ◽  
The Cross

Experimental Assessment of High Temperature Formability of Boron Steel Sheet Manufactured With a Spring Compound Bending Die

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Yang Li ◽  
Yong-Phil Jeon ◽  
Chung-Gil Kang
Keyword(s):  
Mechanical Properties ◽  
Heating Temperature ◽  
Boron Steel ◽  
Hot Press ◽  
Forming Process ◽  
Steel Sheets ◽  
Press Forming ◽  
Bending Process ◽  
Tension Testing ◽  
Hot Press Forming

Bending behavior occurs in the hot press forming process, resulting in many cases of failure during forming. To address the problem of cracking and improve the formability and mechanical properties of boron steel sheets in the bending process, an experiment has been carried out by using a spring compound bending die. Also, a comparison has been made between the traditional U-bending die and the spring compound bending die with regard to formability. The influence of the parameters for hot press forming such as the heating temperature, punch speed, and die radii on the mechanical properties and microstructure was analyzed by tension testing and metallographic observations.

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