Energy efficiency of cold roll forming process
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Cold roll forming is an important sheet metal forming process for the mass production of a variety of complex profiles out of a wide spectrum of materials and thicknesses. The energy efficiency of such a continuous bending process may lead to a significant reduction in energy consumption. In this paper, the energy efficiency indicator is introduced for the case of roll forming. In order for this indicator to be calculated, analytical models are proposed and developed for the estimation of the energy consumption and the production rate. An application to a U-section profile and the effects of the process parameters on the energy efficiency indicator are discussed. The overall contribution (in percent) of the main process parameters on the energy efficiency indicator is calculated through a matrix of experiments. The results have shown that the most influential process parameters, on the energy efficiency of the cold roll forming process, are the bending angle concept, the line velocity, and the inter-distance among the roll stations.
KeywordsCold roll forming Energy efficiency indicator Deformation work Power consumption
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