Advertisement

Numerical Simulation and Sensitivity Analysis of Parameters for Multistand Roll Forming of Channel Section With Outer Edge

  • Guo Zeng
  • Xin-min Lai
  • Zhong-qi Yu
  • Zhong-qin Lin
Article

Abstract

Cold roll forming is a high production but complex metal forming process under the conditions of coupled effects with multi-factor. A new booting finite element method (FEM) model using the updated Lagrangian (UL) method for multistand roll forming process is developed and validated. Compared with most of the literatures related to roll forming simulation, the new model can take the roll rotation into account and is well suited for simulating multistand roll forming. Based on the model, the process of a channel section with outer edge formed with twelve passes is simulated and the sensitivity analysis of parameters is conducted with orthogonal design combined FEM model It is found that the multistand roll forming process can be efficiently analyzed by the new booting model, and sensitivity analysis shows that the yield strength plays an important role in controlling the quality of the products.

Key words

cold roll forming multistand roll forming sensitivity FEM model 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. [1]
    Kiuchi M, Koudabashi T. Automated Design System of Optimal Roll Profiles for Cold Roll Forming [A]. Bedford, eds. Proceedings of the Third International Conference on Rotary Metalworking Processes [C]. Kyoto: IFS (Conference) Ltd, 1984. 423.Google Scholar
  2. [2]
    McClure C, Li H. Roll Forming Simulation Using Finite Element Analysis [J]. Manuf Rev, 1995, 8(2): 114.Google Scholar
  3. [3]
    Bhattacharya D, Smith P D. The Development of Longitudinal Strain in Cold Roll Forming and Its Influence on Product Straightness [A]. The Japan Soc for Tech of Plasticity, ed. First International Conference on Technology of Plasticity [C]. Tokyo, The Japan Soc for Tech of Plasticity, 1984. 422.Google Scholar
  4. [4]
    Brunet M. Numerical Analysis of Cold-Forming Residual Stresses in Thin Walled Structures [A]. Jean-Loup Chenot, eds. Proceedings of the Fourth NUMIFORM Conference [C]. Rotterdam: Taylor and Francis Inc, 1992. 427.Google Scholar
  5. [5]
    Senanayake R S, Cole I M, Thiruvarudchelvan S. The Application of Computational and Experimental Techniques to Metal Deformation in Cold Roll Forming [J]. Journal of Materials Processing Technology, 1994, 45(1–4): 155.CrossRefGoogle Scholar
  6. [6]
    Nefussi G, Gilormini P. A Simplified Method for the Simulation of Cold Roll Forming [J]. International Journal of Mechanical Sciences, 1993, 35(10): 867.CrossRefGoogle Scholar
  7. [7]
    Panton S M, Duncan J L, Zhu S D. Longitudinal and Shear Strain Development in Cold Roll Forming [J]. Journal of Materials Processing Technology, 1996, 60(1–4): 219.CrossRefGoogle Scholar
  8. [8]
    Zhu S D. Theoretical and Experimental Analysis of Roll Forming [D]. New Zealand, University of Auckland, 1993.Google Scholar
  9. [9]
    Heislitz F, Livatyali H, Ahmetoglu M A, et al. Simulation of Roll Forming Process With 3-D FEM Code PAM-STAMP [J]. Journal of Materials Processing Technology, 1996, 59(1–2): 59.CrossRefGoogle Scholar
  10. [10]
    Han Z W, Ren L Q, Liu C, et al. Modelling of Cold Roll Forming of Steel Strip [J]. Materials Science and Technology, 2001, 17(4): 415.CrossRefGoogle Scholar
  11. [11]
    Alsamhan A, Hartely P, Pillinger I. The Computer Simulation of Cold-Roll-Forming Using FE Methods and Applied Real Time Re-Meshing Techniques [J]. Journal of Materials Processing Technology, 2003, 142(1): 102.CrossRefGoogle Scholar
  12. [12]
    Salmani T M, Hartley P, Naeini H, et al. Localised Edge Buckling in Cold Roll-Forming of Symmetric Channel Section [J]. Thin-Walled Structures, 2006, 44(2): 184.CrossRefGoogle Scholar
  13. [13]
    Lindgren M. Cold Roll Forming of a U-Channel Made of High Strength Steel [J]. Journal of Materials Processing Technology, 2007, 186(1–3): 77.CrossRefGoogle Scholar
  14. [14]
    Tsung C C. An Analysis of Forming Limit in the Elliptic Hole-Flanging Process of Sheet Metal [J]. Journal of Materials Processing Technology, 2007, 193(3): 373.MathSciNetGoogle Scholar
  15. [15]
    Bathe K J. Finite Element Procedures [M]. Englewood Cliffs: Prentice-Hall, 1996.Google Scholar
  16. [16]
    Panton S M, Zhu S D, Duncan J L. Geometric Constraints on the Forming Path in Roll Forming Channel Sections [J]. Proceedings of the Institution of Mechanical Engineers, Part B, Journal of Engineering Manufacture, 1992, 206(2): 113.CrossRefGoogle Scholar
  17. [17]
    ABAQUS. ABAQUS Analysis User’s Manual [M]. South Bend, Hibbitt Karlsson and Sorensen Inc, 2004.Google Scholar
  18. [18]
    Bui Q V, Papeleux L, Boman R, et al. Numerical Simulation of Cold Roll Forming Process [A]. Dorel Banabic, eds. Proceedings of the Eighth ESAFORM Conference on Material Forming [C]. Cluj-Nàpoca, The Romanian Academy Publishing House Bucharest, 2005. 141.Google Scholar

Copyright information

© China Iron and Steel Research Institute Group 2009

Authors and Affiliations

  • Guo Zeng
    • 1
  • Xin-min Lai
    • 1
    • 2
  • Zhong-qi Yu
    • 1
  • Zhong-qin Lin
    • 1
    • 2
  1. 1.Shanghai Jiao Tong UniversitySchool of Mechanical EngineeringShanghaiChina
  2. 2.State Key Laboratory of Mechanical System and VibrationShanghaiChina

Personalised recommendations