scholarly journals Theoretical Analysis of Five-Point Bending and Springback for Preforming Process of ERW Pipe FFX Forming

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Lidong Ma ◽  
Haoxi Ma ◽  
Zijian Liu ◽  
Shuo Chen
Keyword(s):  
Theoretical Analysis ◽  
Roll Forming ◽  
Maximum Deviation ◽  
Forming Mechanism ◽  
Roll Bending ◽  
Mathematical Expressions ◽  
Electric Resistance Welding ◽  
Bending Process ◽  
Flexible Roll ◽  
Springback Angle

Flexible forming excellent (FFX) forming of electric resistance welding (ERW) pipe is an advanced roll forming method. In order to understand FFX forming mechanism and set reasonable roll parameters, five-point bending process and springback process for preforming section of ERW pipe FFX forming are analyzed. Under various assumptions, the bending process of sheet metal is divided into full elastic bending stage and elastic-plastic bending stage by analyzing the forming law and simplifying the contact state model of roll bending process. Based on the theory of plane bending theory, the five-point bending springback model is established. Mathematical expressions of bending curvature and rotation angle of arbitrary particle on plate under arbitrary state are derived. The curvature calculation formulas of each particle on plate after springback are obtained, and then the calculation formulas of bending angle and rebound angle after springback are obtained. The theoretical analysis results are verified by the wide plate five-point bending experiment. The theoretical value of springback angle agrees well with the experimental results. The maximum deviation of springback angle is 0.42 degrees. The results show that the five-point bending model is reasonable. It provides theoretical support for the preforming model of flexible roll forming.

Comparison of Bending of Automotive Steels in Roll Forming and in a V-Die

2012 ◽  
Vol 504-506 ◽  
pp. 797-802 ◽  
Author(s):  
Matthias Weiss ◽  
Jascha Marnette ◽  
Preston Wolfram ◽  
Jon Larrañaga ◽  
Peter D. Hodgson
Keyword(s):  
Analytical Equation ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Cold Roll ◽  
Bending Process ◽  
Roll Forming Process ◽  
Springback Angle ◽  
Die Forming ◽  
Good Agreement

Bending in a V-die has been used to indicate the outcome of bending in cold roll forming, although little direct correlation has been performed. In this work direct comparison of the springback in both processes was performed using six samples of automotive steels in a conventional roll forming line where the transverse springback is measured. A bend of similar radius was formed in a V-die and the springback determined. In general, the springback in V-die forming was greater than in roll forming, in some cases by a factor of 2. The theoretical springback angle was determined for all steels using a simple and approximate analytical equation and compared to the experimental roll forming and bending results. While for the roll forming process good agreement was achieved the theoretical values significantly underestimated springback in the V-bending process.

scholarly journals Research on Comparison of Simulation and Experiment in Warpage Defects in Roll Forming Process of the Cap-Shaped Part Using a Five-Boundary Condition Forming Angle Distribution Function

2021 ◽  
Author(s):  
Mingyan Wang ◽  
Zhengyang Feng ◽  
Rui Wang ◽  
Guosong Zhang ◽  
Yuting Lv ◽  
...  
Keyword(s):  
Boundary Condition ◽  
Distribution Function ◽  
Sheet Thickness ◽  
Roll Forming ◽  
Maximum Deviation ◽  
Angle Distribution ◽  
Roll Bending ◽  
Shaped Part ◽  
Forming Angle

Abstract Warpage is one of the main defects in multi-pass roll forming. It manifests as the horizontal deviation in the sheet flange part after forming, impacting the final quality of the sheet. In this manuscript, we focus on the cap-shaped part of a small section profile. Considering the lack of previous scientific guidance on the distribution of forming angles—angles that lead to warpage defects and other defects reducing the quality of these products—a five-boundary condition distribution function of forming angle is proposed. We propose a mechanism for warpage defects in roll bending of a cap-shaped part based on this five-boundary condition forming angle distribution function. Furthermore, we examine the effects of forming angle, sheet thickness, and material yield strength on the warpage defects by examining the designed fluctuation of the edge wave, ∆z, and the maximum deviation of the profile curves of the flange edge, z', to test this theory, roll bending experiments are compared to simulation.

Analysis of Flexible Roller Parameters Influences on Roll Forming of Three-Dimensional Parts

2014 ◽  
Vol 875-877 ◽  
pp. 450-454
Author(s):  
Jiao Jiao Zhen ◽  
Zhi Qing Hu ◽  
Zeng Ming Feng ◽  
Jun Hui Cao
Keyword(s):  
Three Dimensional ◽  
Roll Forming ◽  
Forming Process ◽  
Bending Process ◽  
Experimental Parameters ◽  
Flexible Roll ◽  
Roll Velocity ◽  
Set Up ◽  
Roll Forming Process

Roll forming is a well known bending process and sheet metals can only be machined into two-dimensional surfaces in traditional roll forming. While with more and more personalized demands, three-dimensional surfaces are widely required. Thus, flexible rollers are used to achieve three-dimensional surfaces. And in order to optimize experimental parameters and to predict experimental results, finite element method (FEM) is developed. In this paper the set-up of flexible roll-forming is described and the process of roll forming is simulated. Then the influences of forming parameters, such as the thickness and the roll velocity, on forming quality of the sheet metal in roll forming process are discussed. The results show that the analysis of flexible roller parameters is practical for the continuous and efficient forming of three-dimensional surfaces.

Analysis on the Straight-End Problem in Thin-Plate Three-Roll Bending

2011 ◽  
Vol 80-81 ◽  
pp. 585-590 ◽  
Author(s):  
Zhong Yr Cai ◽  
Ying Wu Lan
Keyword(s):  
Theoretical Analysis ◽  
Thin Plate ◽  
Analytical Solutions ◽  
Numerical Examples ◽  
Roll Bending ◽  
Bending Process ◽  
Bending Behavior ◽  
Loading And Unloading ◽  
Set Up

The analytical solutions for the deformations of straight-ends in three-roll bending process of thin-plate were presented. Based on the theoretical analysis on the loading and unloading during roll-bending, the curvature equations governing the bending behavior of thin-plate were set up and then solved by integration. Numerical examples were given to illustrate the application of the solutions. The curvature and deflection distributions on straight-ends were shown in graphically and discussed.

Sideways Movement of Strip in In-Plane Roll-Bending Process with Conical Rollers

2010 ◽  
Vol 154-155 ◽  
pp. 1419-1422
Author(s):  
Zhi Jun Li ◽  
He Yang ◽  
Heng Li ◽  
Jing Liu
Keyword(s):  
Maximum Deviation ◽  
Fe Simulations ◽  
Roll Bending ◽  
Bending Process ◽  
Deviation Ratio

As a result of unequal reduction, the sideways movement of the strip at the entry is occurred in in-plane roll-bending process with conical rollers. This will reduce the shape quality of the formed ring. To control the sideways movement, FE simulations with applying unilateral and bilateral guide planes are carried out by employing ABAQUS/Explicit code. The results show that, the strip moves towards the bottom end and scratches with guide plane at the trailing end if applying unilateral guide plane; the sideways movement can be controlled effectively with circularity of 0.993 and maximum deviation ratio of 12.5% for the formed ring if applying bilateral guide planes.

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
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