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.

Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm

2012 ◽  
Vol 504-506 ◽  
pp. 857-862 ◽  
Author(s):  
Ahmad Abrass ◽  
Thomas Kessler ◽  
Peter Groche
Keyword(s):  
Numerical Algorithm ◽  
Numerical Algorithms ◽  
Roll Forming ◽  
Design Parameters ◽  
Fe Model ◽  
Forming Process ◽  
Cross Sectional ◽  
Cross Sectional Profile ◽  
Sectional Profile ◽  
Roll Forming Process

For the manufacturing of large quantities of profile-shaped products, the roll forming process represents one of the most effective metal forming technologies. During this process, the sheet metal will be formed into a desired cross-sectional profile using successive pairs of forming rolls. This process is well known as a very complex process in industry because of the multiplicity of the process and design parameters. For that reason, the optimization of roll forming processes using numerical methods like the finite element method is very complex and time-consuming. In this paper, a numerical method will be introduced to accelerate the simulation and to optimize the roll forming process. The newly developed algorithm will be illustrated and validated by analyzing the roll forming process. The details of the FE-model and the numerical algorithm will be described. Furthermore, the results of the numerical simulation with and without the application of the numerical algorithms will be compared. Finally, the process will be optimized using the newly developed method.

Properties Uniformity Analysis of Cold Formed Steel Sheet Piling

2012 ◽  
Vol 174-177 ◽  
pp. 102-108 ◽  
Author(s):  
Guang Hong Feng ◽  
Hong Liang Zhang ◽  
Pei Zhang ◽  
Xu Chang Zhou ◽  
Yong Zhao
Keyword(s):  
Cross Section ◽  
Steel Sheet ◽  
Performance Test ◽  
Steel Production ◽  
Test Method ◽  
Roll Forming ◽  
Metallographic Analysis ◽  
Complex Cross ◽  
Complex Cross Section ◽  
Cold Formed Steel

Through analyzing the molding process characteristics of cold-formed steel sheet piling, mechanical testing and metallographic analysis was made on the curved position of the U-shaped cold-formed steel sheet piling , the following conclusions was drawn: Cold formed steel sheet pile was subjected to the complex cross-section cold roll forming process, resulting in the uneven performance of a steel sheet piling along the horizontal. For the open cold formed steel of asymmetric steel sheet piling and complex cross section, a simple test at flat panel location is difficult to represent the overall performance of cold-formed steel, therefore it is necessary to make a comprehensive performance test on locking. A test method to check the locking occlusion performance on the cold bending steel plate is put forward. The experimental tensile strength of the Q235 level of ordinary carbon steel production of cold-formed steel sheet piling locking bite is 66MPa.

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 Simulation Study on Stress and Strain Change Rule for Channel Steel Cold Roll Forming Process

2012 ◽  
Vol 511 ◽  
pp. 183-187
Author(s):  
Lin Chen ◽  
Chen Xia Wu ◽  
Yan Wang
Keyword(s):  
Equivalent Strain ◽  
Roll Forming ◽  
Stress And Strain ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Finite Element Software ◽  
Cold Roll ◽  
Strain Change ◽  
Simulation Results ◽  
Roll Forming Process

The paper describes the research on deformation mechanism method of channel steel cold roll forming by finite element software ABAQUS, and typically analyzes stress and strain change rule of the fifth pass cold-formed process. Simulation results show that: on the whole, the equivalent strain and stress value of three typical parts tend to increasing with time increases

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