FEM Modeling and Mechanics Analysis of Flexible Roll Forming

2010 ◽  
Vol 44-47 ◽  
pp. 132-137 ◽  
Author(s):  
Yu Yan ◽  
Qiang Li
Keyword(s):  
Equivalent Stress ◽  
Sheet Thickness ◽  
Deep Understanding ◽  
Product Line ◽  
Roll Forming ◽  
Variable Cross ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Forming Defects

Flexible roll forming is a new forming process that produces parts with variable cross sections. This forming process is proposed to meet the need in the weight reduction of automobiles. With deep understanding of this process and reasonable simplification, the FEM model of a nine-step flexible roll forming of an ultra-high-strength steel bumper is established. In order to analyze the mechanics and the deformation characteristics of the flexible roll forming, equivalent stress, equivalent strain, sheet thickness and springback amount are extracted from the simulation result and studied comparatively, which is of great importance to understand the appearance of the forming defects. In addition, the forming load and torque of the rollers can also be obtained which can guide the design of the flexible roll forming product line.

FEA Analysis on 600MPa TRIP Steel Variable Section Roll Forming with Protrusion and Hole

2012 ◽  
Vol 457-458 ◽  
pp. 299-303 ◽  
Author(s):  
Wen Fang Peng ◽  
Qiang Li ◽  
Yu Yan
Keyword(s):  
Trip Steel ◽  
Equivalent Stress ◽  
Sheet Thickness ◽  
Deep Understanding ◽  
Equivalent Strain ◽  
Product Line ◽  
Roll Forming ◽  
Forming Process ◽  
Variable Section ◽  
Forming Defects

Trip steel is broadly used in automobile manufacturing with its high strength and enhanced formability. For the variable section parts with protrusion and hole, roll forming is a kind of feasible way to realize continuous parts manufacturing, In the paper, with deep understanding of roll forming process and reasonable simplification, the FEM model of a multi-step variable section roll forming of 600MPa trip steel parts with protrusion and hole is established to analyze the mechanics and the deformation characteristics of the forming procedure. Equivalent stress, equivalent strain, sheet thickness and springback amount are extracted from the simulation result and studied comparatively, which is of great importance to understand the appearance of the forming defects. In addition, the forming load and torque of the rollers can also be obtained to guide the design of the variable section roll forming product line.

Analysis of Flexible Roll Forming Process with Arc Shape Panel

2015 ◽  
Vol 799-800 ◽  
pp. 439-442
Author(s):  
Ya Zhang ◽  
Dae Hwan Yoon ◽  
Dong Won Jung
Keyword(s):  
Cross Sections ◽  
High Strength ◽  
Variable Cross Section ◽  
Roll Forming ◽  
Variable Cross ◽  
Transportation Engineering ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Arc Shape

Roll forming is a highly useful and important forming technique for sheet metal. As an economic profile product, roll forming products are widely used in transportation, engineering machinery, and civil construction because of their uniform sections, high strength, and low energy consumption[1]. Roll forming is a rapid processing operation used for transforming flat sheets of material into useful profiled sections. However, a lot of components used in the automobile, railway cars, ship construction, and building industries have variable cross sections. Therefore, flexible roll forming was developed recently to produce variable cross section profiles.

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.

Application of Support Vector Regression and Genetic Algorithm to Reduce Web Warping in Flexible Roll-Forming Process

2020 ◽  
Vol 143 (3) ◽  
Author(s):  
Young Yun Woo ◽  
Dae-Cheol Ko ◽  
Taekyung Lee ◽  
Yangjin Kim ◽  
Ji Hoon Kim ◽  
...  
Keyword(s):  
Process Parameters ◽  
Optimization Method ◽  
Roll Forming ◽  
Support Vector ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Roll Forming Process ◽  
Web Warping ◽  
The Web

Abstract In a flexible roll-forming process, a metal blank is incrementally deformed into the desired shape with a variable cross-sectional profile by passing the blank through a series of forming rolls. Because of the combined effects of process and material parameters on the quality of the roll-formed product, the approaches used to optimize the roll-forming process have been largely based on experience and trial-and-error methods. Web warping is one of the major shape defects encountered in flexible roll forming. In this study, an optimization method was developed using support vector regression (SVR) and a genetic algorithm (GA) to reduce web warping in flexible roll forming. An SVR model was developed to predict the web-warping height, and a response surface method was used to investigate the effect of the process parameters. In the development of these predictive models, three process parameters—the forming-roll speed condition, leveling-roll height, and bend angle—were considered as the model inputs, and the web-warping height was used as the response variable. The GA used the web-warping height and the cost of the roll-forming system as the fitness function to optimize the process parameters of the flexible roll-forming process. When the flexible roll-forming process was carried out using the optimized process parameters, the obtained experimental results indicated a reduction in web warping. Hence, the feasibility of the proposed optimization method was confirmed.

Modeling and Simulation of Continuous Flexible Roll Forming Process

2013 ◽  
Vol 365-366 ◽  
pp. 549-552
Author(s):  
Zhou Sui ◽  
Zhong Yi Cai ◽  
Ming Zhe Li
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Rigid Bodies ◽  
Roll Forming ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Roll Forming Process

The continuous flexible roll forming process is a novel sheet metal forming technique for effectively manufacture of three-dimensional surface parts. In this study, two types of finite element (FE) models were developed under the ABAQUS/Explicit environment. The difference of the two models is that the rolls are defined as discrete rigid bodies in model No.1 and are deformable in model No.2. An experiment was carried out using the continuous sheet metal forming setup. The comparison of the numerical computation results with the experimental results shows that the model No.2 can be used for the shape prediction of continuous flexible roll forming process well.

scholarly journals Flange Wrinkling in Flexible Roll Forming Process

2014 ◽  
Vol 81 ◽  
pp. 245-250 ◽  
Author(s):  
Mohammad Mehdi Kasaei ◽  
Hassan Moslemi Naeini ◽  
Behnam Abbaszadeh ◽  
Mehran Mohammadi ◽  
Mojtaba Ghodsi ◽  
...  
Keyword(s):  
Roll Forming ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Flange Wrinkling ◽  
Roll Forming Process

The flower pattern and rolls design for ERW pipes with the different specification in the flexible roll forming process

2020 ◽  
Vol 154 ◽  
pp. 106809
Author(s):  
Jiaojiao Cheng ◽  
Jianguo Cao ◽  
Jianwei Zhao ◽  
Jiang Liu ◽  
Rongguo Zhao ◽  
...  
Keyword(s):  
Roll Forming ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Roll Forming Process
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