FEM Simulation of Main Deformation during Cage Roll-Forming Process

2013 ◽  
Vol 395-396 ◽  
pp. 1239-1242
Author(s):  
Sheng De Hu ◽  
Jing Zhang ◽  
Li Xin Li ◽  
Yong Liu
Keyword(s):  
Plastic Strain ◽  
High Frequency ◽  
Fem Simulation ◽  
Element Model ◽  
Roll Forming ◽  
Effective Plastic Strain ◽  
Linear Section ◽  
Forming Process ◽  
Roll Forming Process ◽  
Main Deformation

Cage roll-forming is an advanced roll-forming technique widely used in high frequency welding (HFW) pipes production. However, to the authors' knowledge, the real cage roll-forming production is mainly on experience rather than science. Few publications can be found on cage roll-forming for its complexity. In order to improve the understanding of the technique, a large deformation elastic-plastic finite element model for the HFW660 cage roll-forming mill was established and simulated through adopting the dynamic explicit algorithm. The distribution of effective plastic strain and the deformed geometry of the strip at the pre-forming and linear section were obtained. The simulation results were validated with the measurements. The results show that the biggest effective plastic strain (EPS) occurs at the center of strip. The distribution of EPS is far from uniform on the cross-section of the strip. This may owe to the uneven distribution of down-hill amount.

The Effect of Flange Length on the Distribution of Longitudinal Strain during the Flexible Roll Forming Process

2018 ◽  
Vol 920 ◽  
pp. 46-51
Author(s):  
Young Yun Woo ◽  
Pil Gyu Kang ◽  
Il Yeong Oh ◽  
Young Hoon Moon
Keyword(s):  
Longitudinal Strain ◽  
Fem Simulation ◽  
Roll Forming ◽  
Variable Cross ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Longitudinal Bow ◽  
Transversal Distribution ◽  
Roll Forming Process

Flexible roll forming is an advanced sheet metal forming process which allows the production of variable cross-section profiles. In flexible roll forming process, nonuniform transversal distribution of the longitudinal strain can cause the longitudinal bow, which is deviation in height of the web over the length of the profile. To investigate the effect of flange length on the transversal distribution of the longitudinal strain, FEM simulations are conducted with different flange length for three blank shapes; trapezoid, convex and concave. The result shows that the longitudinal strain and longitudinal bow decrease with increasing flange length for a trapezoid and a concave blank. For a convex blank, the longitudinal strain and longitudinal bow increase with increasing flange length. To validate FEM simulation result, numerically obtained longitudinal strain has been compared with experimental results.

Solid Shell Element and its Application in Roll Forming Simulation

2007 ◽  
Vol 340-341 ◽  
pp. 347-352 ◽  
Author(s):  
Da Yong Li ◽  
Ying Bing Luo ◽  
Ying Hong Peng
Keyword(s):  
Degrees Of Freedom ◽  
Shell Element ◽  
Element Model ◽  
Roll Forming ◽  
Good Prospect ◽  
Solid Shell ◽  
Forming Process ◽  
Forming Simulation ◽  
Assumed Natural Strain ◽  
Roll Forming Process

Solid shell element models which possess only translational degrees of freedom and are applicable to thin structure analyses has drawn much attention in recent years and presented good prospect in sheet metal forming. In this study, a solid shell element model is introduced into the dynamic explicit elastic-plastic finite element method. The plane stress constitutive relation is assumed to relieve the thickness locking and the selected reduced integration method is used to overcome volumetric locking. The assumed natural strain method is adopted to resolve shear locking and trapezoidal locking problem. Two benchmark examples and a stage of roll forming process are calculated, and the calculating results are compared with those by solid element model, which demonstrates the effectiveness of the element.

Finite Element Analysis for the Roll Forming Process of Rib

2018 ◽  
Vol 878 ◽  
pp. 302-307
Author(s):  
Dong Won Jung
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Equivalent Plastic Strain ◽  
Von Mises Stress ◽  
Roll Forming ◽  
Thickness Variation ◽  
Forming Process ◽  
Element Analysis ◽  
High Production Rate ◽  
Roll Forming Process

Roll forming is a continuous profile production process to form sheet metal progressively into the desired shape with closer tolerances. The process offers several advantages such as complex geometrical shapes, high strength, dimensional accuracy, closer tolerances, better quality and consistency, high production rate, improved conformity, and good surface finish. Several parts of automobile body are produced with this process. Nowadays roll forming technology draws more attentions than before in the automotive industry. In this paper, A Finite Element Method applied to study von mises stress, equivalent plastic strain, thickness, plastic strain, longitudinal strain and spring back of the metal sheet with ribs formed by roll forming process. The thickness variation was almost -6.144%.

A Finite Element Model of Orthogonal Metal Cutting

1985 ◽  
Vol 107 (4) ◽  
pp. 349-354 ◽  
Author(s):  
J. S. Strenkowski ◽  
J. T. Carroll
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Effective Plastic Strain ◽  
Orthogonal Metal Cutting ◽  
Chip Separation ◽  
Chip Geometry

A finite element model of orthogonal metal cutting is described. The paper introduces a new chip separation criterion based on the effective plastic strain in the workpiece. Several cutting parameters that are often neglected in simplified metal-cutting models are included, such as elastic-plastic material properties of both the workpiece and tool, friction along the tool rake face, and geometry of the cutting edge and workpiece. The model predicts chip geometry, residual stresses in the workpiece, and tool stresses and forces, without any reliance on empirical metal cutting data. The paper demonstrates that use of a chip separation criterion based on effective plastic strain is essential in predicting chip geometry and residual stresses with the finite element method.

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