scholarly journals Development of a Roll-Forming Process of Linearly Variable Symmetric Hat-type Cross-section

2015 ◽  
Vol 14 (4) ◽  
pp. 118-125 ◽  
Author(s):  
Kwang-Heui Kim ◽  
Moon-Chul Yoon
Keyword(s):  
Cross Section ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Validation of a FEM Model for the Simulation of the Cold Roll Forming Process

2015 ◽  
Vol 651-653 ◽  
pp. 219-224 ◽  
Author(s):  
Antonio Formisano ◽  
F. Capece Minutolo ◽  
Antonio Caraviello ◽  
Luigi Carrino ◽  
Massimo Durante ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Technological Process ◽  
Cross Section ◽  
Circular Cross Section ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Fem Model ◽  
Cold Roll ◽  
Roll Forming Process

Cold roll forming is a process for plastic deformation, which allows realizing profiles, with a defined section and established length, from the plastic deformation of a metal sheet. The sheet is induced to cross several stands of rolls, arranged along the same axis of advancing. The rolls induce plastic deformation in the sheet and then lead it to the desired geometric configuration. In order to control the geometric parameters of the plate during the profiling, it was created a FEM model to simulate the final stage of the technological process, developed by an industrial production line of a company located in Naples (Italy), that sells tubes with several cross sections. In this phase, the semi-finished product, having a circular cross section, is forced to cross through four stands of rolls. In this way, it changes the geometric condition of the cross section from circular to square. The model was carried out using a non-linear calculation code, which allows analyzing the parameters of interest in the different process steps. The results, obtained numerically, were compared with the experimental ones through the measurement of five specimens, obtained directly from technological process. The values of percentage deviation, regarding the external dimension and the thickness, for each step of advancement, do not exceed the 3% of error. Then, the analysis results denote the capability to simulate the cold roll forming process using finite element method.

A 3D FE Model for Roll Forming of Ring with Complex Cross Section

2012 ◽  
Vol 538-541 ◽  
pp. 788-791
Author(s):  
Gang Yao Zhao ◽  
Ran Yang Zhang ◽  
Zheng Hua Guo ◽  
Zhan Rong Feng ◽  
Shuai Ying
Keyword(s):  
Cross Section ◽  
Equivalent Strain ◽  
Roll Forming ◽  
Fe Model ◽  
Forming Process ◽  
Geometry Modeling ◽  
Complex Cross ◽  
Complex Cross Section ◽  
Materials Modeling ◽  
Roll Forming Process

The roll forming process is a technique for forming ring with complex cross section, which widely used in the fields of aviation, aerospace and other high technology industries. To predict and control the roll forming quality, a 3D elastic-plastic finite element (FE) model of ring with complex cross section for roll forming was developed using the explicit code ABAQUS/Explicit. During the modeling process, several key techniques are solved, such as materials modeling, geometry modeling and grid optimal design. Then the reliability of the model was verified. Furthermore, numerical simulation and analysis of the roll forming process of ring with complex cross section have been carried out by using the model. The distribution regularities of equivalent strain in the process have been analyzed. The results show that with the progressing of roll forming, the equivalent strain increase sharply in the initial stage, then slightly varies, and the W shape of ring cross section is produced gradually.

Computerized Numerical Simulation of Roll-Forming Process

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 239-242 ◽  
Author(s):  
Manabu Kiuchi ◽  
Kenji Abe ◽  
Ryu Onodera
Keyword(s):  
Numerical Simulation ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Quadrilateral Shape Rib Forming by Roll Forming Process

2018 ◽  
Vol 878 ◽  
pp. 296-301
Author(s):  
Dong Won Jung
Keyword(s):  
Automotive Industry ◽  
High Strength Steel ◽  
Numerical Study ◽  
Thickness Distribution ◽  
High Strength ◽  
Metal Sheet ◽  
Product Performance ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

The roll forming is one of the simplest manufacturing processes for meeting the continued needs of various industries. The roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for making structural components. In order to reduce the thinning of the sheet product, traditionally the roll forming has been suggested instead of the stamping process. The increased product performance, higher quality, and the lowest cost with other advantages have made roll forming processes suitable to form any shapes in the sheets. In this numerical study, a Finite Element Method is applied to estimate the stress, strain and the thickness distribution in the metal sheet with quadrilateral shape, ribs formed by the 11 steps roll forming processes using a validated model. The metal sheet of size 1,000 × 662 × 1.6 mm taken from SGHS steel was used to form the quadrilateral shape ribs on it by the roll forming process. The simulation results of the 11 step roll forming show that the stress distribution was almost uniform and the strain distribution was concentrated on the ribs. The maximum thinning strain was observed in the order of 15.5 % in the middle rib region possibly due to the least degree of freedom of the material.

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