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.

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.

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.

Explicit Simulation of Roll Forming Process with EAS Solid-shell Elements

2010 ◽  
Author(s):  
L. M. Li ◽  
Y. H. Peng ◽  
D. Y. Li ◽  
F. Barlat ◽  
Y. H. Moon ◽  
...  
Keyword(s):  
Roll Forming ◽  
Solid Shell ◽  
Forming Process ◽  
Shell Elements ◽  
Explicit Simulation ◽  
Roll Forming Process

scholarly journals Numerical Modeling and Digital Image Correlation Strain Measurements of Coated Metal Sheets Submitted to Large Bending Deformation

2013 ◽  
Vol 554-557 ◽  
pp. 2424-2431
Author(s):  
Laurent Duchêne ◽  
Amine Ben Bettaieb ◽  
Victor Tuninetti ◽  
Anne Marie Habraken
Keyword(s):  
Digital Image Correlation ◽  
Digital Image ◽  
Shell Element ◽  
Numerical Results ◽  
Image Correlation ◽  
Integration Scheme ◽  
Forming Process ◽  
Coated Metal ◽  
Assumed Strain ◽  
Assumed Natural Strain

The recently developed SSH3D solid-shell element [1], which is based on the Enhanced Assumed Strain (EAS) and the Assumed Natural Strain (ANS) techniques, is utilized for the modeling of a severe bending sheet forming process. To improve the element's ability to capture the through thickness gradients, a specific integration scheme was developed. In this paper, the performances of this element for the modeling of the T-bent process were assessed thanks to comparison between experimental and numerical results in terms of the strain field at the outer surface of the sheet. The experimental results were obtained by Digital Image Correlation. It is shown that a qualitative agreement between experimental and numerical results is obtained but some numerical parameters should be optimized to improve the accuracy of the simulation predictions. In this respect, the influence of the penalty coefficient of the contact modeling was analyzed.

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