Study on the Spring-Back Effect with Stress Distribution According to Forming Sheet Width in the Roll Forming Process

2015 ◽  
Vol 789-790 ◽  
pp. 116-120
Author(s):  
Dong Hong Kim ◽  
Hao Yu ◽  
Dong Won Jung
Keyword(s):  
Stress Distribution ◽  
Roll Forming ◽  
Spring Back ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Sheet Width ◽  
Simulation Results ◽  
The Relationship ◽  
Roll Forming Process

This study, based on finite element analysis, analyzed the spring back phenomenon and stress distribution of forming sheets (HTS) in the roll forming process. By comparison of the stress distribution, this study analyzed two kinds of simulation. The first simulation performed simple bending simulation before roll forming simulation. With reference to the first simulation results, the second simulation analyzed the relationship between the stress distribution and the phenomenon of spring back. We also studied the stress distribution effect for spring back in the forming sheet.

Velocity Control with SGARC 440 Alloy in the Roll Forming Process

2015 ◽  
Vol 1095 ◽  
pp. 894-897
Author(s):  
Ya Zhang ◽  
Dong Hong Kim ◽  
Dong Won Jung
Keyword(s):  
Theory And Practice ◽  
Roll Forming ◽  
Velocity Control ◽  
Spring Back ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Strip Metal ◽  
Roll Forming Process

Cold roll-forming of metal sections is a significant field in advancing forming of strip metal, and the forming processes are influenced by many factors. The scientific design of passes is worked out by combining theoretical analysis with finite element analysis, in accordance with the principles of cold roll-forming; thus the desired high-quality bending sections are achieved through a combination of theory and practice. This study mainly addresses the velocity of the rolls for sheets that have angle sides, and the spring-back of SGARC 440 alloy sheets in the roll forming process, where we use DEFORM to simulate the sheet.

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

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.

Verification of Numerical Roll Forming Loads with the Aid of Measurement Equipment

2014 ◽  
Vol 939 ◽  
pp. 373-380 ◽  
Author(s):  
Peter Groche ◽  
Christian Mueller ◽  
Lars Baeumer
Keyword(s):  
Numerical Model ◽  
Process Design ◽  
Mass Production ◽  
Roll Forming ◽  
Measurement Equipment ◽  
Forming Process ◽  
Forming Simulation ◽  
Roll Forming Process

Roll forming is an important forming process for profile manufacturing in mass production. The design of the process has an important influence on the quality of the products. Therefore, the knowledge of the occurring loads during the roll forming process, e.g. forces and pressures, is essential for the process design. However, the experimental determination of the occurring contact normal pressures in roll forming processes poses a challenge. Finite element simulations offer the potential to approximate contact normal loads and thus, enable a better process design. Nevertheless, due to simplifications of the numerical model, a realistic and reliable output of loads in roll forming is not possible. An enhanced numerical model could provide more valuable information. This paper will demonstrate the reproduction of realistic contact normal pressures and load forces in a roll forming simulation. To verify the numerical values, they will be compared to data gained by experiments.

Investigation on Variation of Bow Defect in Roll Forming Process

2017 ◽  
Vol 729 ◽  
pp. 80-85
Author(s):  
Dong Won Jung
Keyword(s):  
Steel Strip ◽  
Sheet Thickness ◽  
Roll Forming ◽  
Spring Back ◽  
Forming Process ◽  
Complex Deformation ◽  
Plastic Forming ◽  
Set Up ◽  
Roll Forming Process ◽  
Abaqus Software

Roll forming is a kind of plastic forming process in which a steel strip is bent by several sets of rolls gradually into the desired shape. The products are cold roll forming steels with various sections. Roll forming is one of the most widely used processes in the world for forming metal. Roll forming is a complex deformation process, which involves large displacement, finite strain and the problems of contact and friction between strip and rolls. This process exhibits obvious geometry, physical and boundary nonliterary. The complex processes contain many aspects such as geometry, kinematics and dynamics, etc. The forming process involves not only transverse bending, but also other additional deformations. In this paper, a group of simulations have been established with ABAQUS software to studying about the spring back and bow defect in the roll forming process. At last, experiments have been accomplished to verify the simulation results. The simulations based on the ABAQUS software calculate the spring back angles and bow displacements. The bow displacement of the roll forming process is considered relate to many factors include inner distance between stands, gaps of the rolls, channel width, the material of the sheet, sheet thickness and so on.To verify the bow displacement in roll forming process, 9 groups of simulations were set up use Taguchi method to figure out the influence on bow displacement of every factor. The longitudinal strain also has been learned in the present study.

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.

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