scholarly journals Finite Element Analysis of Stretch Forming of an Open Profile Made of Ultra-High Strength Martensitic MS1500 Steel

2021 ◽  
Author(s):  
Mehmet Okan Görtan ◽  
Ümit Türkmen
Keyword(s):  
Finite Element ◽  
High Strength ◽  
Roll Forming ◽  
Sheet Metals ◽  
Stretch Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Open Profile ◽  
Fe Simulations ◽  
Forming Characteristics

Stretch forming process is primarily used for generating curved structures from sheet metals such as car body panels or aircraft fuselage panels. Although there are large number of studies about stretch forming, these investigations focus mainly on flat sheet metals. However, various parts especially in the automotive industry, such as passenger car fenders are first preformed to a profile and afterwards stretch formed to generate desired final geometry. Moreover, as a consequence of weight reduction activities, these fender parts are usually made of ultra-high strength steels (UHSS) in the last two years. In the current study, stretch forming characteristics of an open profile made of martensitic UHSS (MS1500) are investigated using finite elements method (FEM). Used geometry was an asymmetrical hat profile which was preformed using roll forming prior to stretch forming. Mechanical properties of the material used is characterized using tensile test and modeled using Swift isotropic strain hardening rule. Strain and stress distribution along the bend section, geometry and springback in the final part as well as forming force have been investigated using finite element (FE) simulations. A twist has been observed in the final product along its longitudinal axis. To validate the FE results, experiments have been conducted. Twist problem is also detected in the manufactured samples. The amount of springback in produced part was similar to the experiments. It is found that FE simulations can model stretch forming process of open profiles accurately.

Numeral Simulation of a New Forming Process: Stretch Forming Combined with Roll Forming

2011 ◽  
Vol 189-193 ◽  
pp. 2399-2403 ◽  
Author(s):  
Zhi Qing Hu ◽  
Ji Zhao ◽  
Yu Shan Deng ◽  
Hao Han Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Von Mises Stress ◽  
Roll Forming ◽  
Stretch Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Formed Part ◽  
Von Mises ◽  
Rubber Rolling

In this study, the principle of the stretch forming combined with roll forming(SRF) is proposed, to present the availability of this process, it is simulated by the Method of Finite Element Analysis(FEA) by comparing traditional stretch forming(SF) with stretch roll forming (SRF), the result is shown that the roller covered the rubber rolling sheet metal is benefit to formed part, such as Von mises stress, the thickness thinned and the coincidence curve of formed part are studied.

418 Cold roll forming process of wrought magnesium alloy using finite element analysis

2014 ◽  
Vol 2014.22 (0) ◽  
pp. 163-164
Author(s):  
Shintaro AKANUMA ◽  
Tomoya SUZUKI ◽  
Hayato ASO ◽  
Bunkyo KYO ◽  
Shinichi NISHIDA ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Magnesium Alloy ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Wrought Magnesium Alloy ◽  
Roll Forming Process

Testing and Modeling of Roll Levelling Process

2014 ◽  
Vol 611-612 ◽  
pp. 1753-1762 ◽  
Author(s):  
Elena Silvestre ◽  
Eneko Sáenz de Argandoña ◽  
Lander Galdos ◽  
Joseba Mendiguren
Keyword(s):  
Finite Element ◽  
High Strength Steels ◽  
Beam Theory ◽  
High Strength ◽  
Theoretical Models ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Design Engineers ◽  
Ultra High Strength Steels

Roll levelling is a forming process used to remove the residual stresses and imperfections of metal strips by means of plastic deformations. During the process the metal fibres are subjected to cyclic tension-compression deformations leading to achieve flat product. The process is especially important to avoid final geometrical errors when coils are cold formed or when thick plates are cut by laser. In the last years, and due to the appearance of high strength materials such as Ultra High Strength Steels, machine design engineers are demanding a reliable tool for the dimensioning of the levelling facilities. In response to this demand, Finite Element Analysis and Analytical methods are becoming an important technique able to lead engineers towards facilities optimization through a deeper understanding of the process. Aiming to this study two different models have been developed to analyze the roll levelling operations: an analytical model and a finite element model. The FE-analysis was done using 2D-modelling assuming plane strain conditions. Differing settings, leveller configuration and materials were investigated. The one-dimensional analytical levelling model is based on classical beam theory to calculate the induced strain distribution through the strip, and hence the evolving elastic/plastic stress distribution. Both models provide a useful guide to process-sensitivities and are able to identify causes of poor leveller performance. The theoretical models have been verified by a levelling experimental prototype with 13 rolls at laboratory.

Finite Element Analysis of Rolling Process to Locally Thin Metal Strips

2018 ◽  
Vol 920 ◽  
pp. 10-15
Author(s):  
Kuang-Jau Fann ◽  
Che Yi Lin ◽  
Ying Ju Chen
Keyword(s):  
Finite Element ◽  
Steel Strip ◽  
Lightweight Design ◽  
Rolling Process ◽  
Roll Forming ◽  
Speed Ratio ◽  
Forming Process ◽  
Element Analysis ◽  
Finite Element Software ◽  
Roll Forming Process

Because of relative low investment cost on the installation of equipment and extensive product quality with other advantages, roll forming process has been broadly applied to produce profiles from steel strip bands and has gradually replaced aluminum profiles made by hot extrusion. Moreover, a lightweight design is the trend for reducing carbon emissions and waste. Therefore, a lightweight design of structures with local thinning used the roll forming production will make metal profiles more market competitiveness. In this study, the commercial Finite Element software DEFORM is used to investigate the rolling process preparing the metal strips with local thinning feature for the subsequent roll forming process to form a lightweight metal profile. Two kinds of roll configuration are used in this study, namely symmetrical and non-symmetrical. The symmetrical rolling process has the same diameter for the upper and the lower roll, while the non-symmetrical rolling process has different diameter in both rolls. As the process parameters, the roll speed ratio between the upper and the lower roll is used for the symmetrical rolling process, while the distance between the axis of the upper and lower roll is used for the non-symmetrical rolling process. As a result, the rolled thinning feature has its sidewalls flaring outwards, so that it has a narrow bottom and a wide opening. Furthermore, it can be regarded as defect that the thickness of the rolled thinning feature is not thinned enough as required and a raising at the opening is observed. In general, increasing the roll diameter or keeping the speed of the two rolls as the same can have a better thinning result for the symmetric rolling. In the non-symmetric rolling, increasing the roll diameter can improve the thickness, but no significant effect can be found by changing the roll diameter ratio.

Development of Evolutionary Method for Optimizing a Roll Forming Process of Aluminum Parts

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Hong Seok Park ◽  
Tran Viet Anh
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Process Parameters ◽  
Roll Forming ◽  
Fe Model ◽  
Forming Process ◽  
Element Analysis ◽  
Modeling And Optimization ◽  
Aluminum Part ◽  
Back Angle

This paper presents the development of the knowledge-based neural network (KBNN) and genetic algorithm (GA) in modeling and optimization of the roll forming (RF) process of aluminum parts. The idea of a KBNN using multifidelity finite element (FE) models was developed to model the mechanical behaviors of the aluminum sheet. Initially, the less costly but less accurate FE model was used to build the response surface functions for the knowledge path of the KBNN. After that, a small number of the more accurate but expensive finite element analysis (FEA) of the high fidelity FE model were utilized in a multilayer perceptron (MLP) neural network with the prior knowledge to produce the KBNN prediction results. Two powerful optimization algorithms, the Levenberg–Marquadrt (LM) and GA, were applied to train the KBNN. The trained KBNN was used to perform the parametric study for investigating the effects of process parameters on the part quality. After that, the optimization of the process parameters was carried out by employing the combination of the GA and KBNN. The optimization objective was minimizing the overall damage in the aluminum part while keeping the longitudinal strain and spring back angle less than allowable limits to prevent the existence of defects. The modeling and optimization results by using the KBNN and GA were compared with the results from other methods to prove the advantages of the developed one against others.

Technology of Finite Element Analysis for Roll Forming Process

2014 ◽  
Vol 941-944 ◽  
pp. 1832-1835
Author(s):  
Xue Feng Peng ◽  
Jing Tao Han ◽  
Jing Liu ◽  
Pei Jie Yan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Computer Aided Design ◽  
Current Status ◽  
Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Element Simulation ◽  
Roll Forming Process

With deepening of roll forming technology and the proficiency of computer aided design and finite element Analysis (FEA) technology, it is widely noted that using the technology of FEA to simulate the roll forming process. In this paper, the current status of finite element simulation for roll forming process at home and abroad is summarized. And the finite element theories of deformation zone in roll forming process are analyzed. The new issues on roll forming process faced by finite element simulation, including advanced high strength steel (AHSS), multipass heterosexual cross section and coupling thermo-mechanical-metallurgical (TMM) coupling etc. are discussed. Moreover, the future trends of numerical simulation about the roll forming process are forecasted.

scholarly journals Method for Controlling Edge Wave Defects of Parts during Roll Forming of High-Strength Steel

Metals ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 53
Author(s):  
Ce Liang ◽  
Sinan Li ◽  
Jicai Liang ◽  
Jiandong Li
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cross Section ◽  
Sheet Thickness ◽  
Edge Wave ◽  
Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Parameter Combination ◽  
Shaped Cross Section

Cold roll forming is suitable for sheet metal processing and can provide a new method for the production and processing of anti-collision beams for commercial vehicles. In order to accurately control the edge wave defects of the parts in the roll forming process, we used the professional roll design software COPRA to design the roll pattern and used the professional finite element analysis software ABAQUS to establish a three-dimensional finite element analysis model of the “b”-shaped cross-section. We analyzed the factors affecting the edge wave by controlling different process parameters (the thickness of the sheet, the height of the flange, and the forming speed), and the best process parameter combination was determined. The results showed that the thickness of the sheet, the height of the flange, and the forming speed all had an effect on the edge wave defects of the “b”-shaped cross-section. The influence of sheet thickness was the greatest, followed by flange height and then forming speed. The final selected parameter combination was a sheet thickness of 3 mm, a flange height of 100 mm, and a forming speed of 150 mm/s. This work provides a theoretical basis for actual production.

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