Accelerating the FE-Simulation of Roll Forming Processes with the Aid of specific Process’s Properties

Abrass, Ahmad; Özel, Mahmut; Groche, Peter

doi:10.1063/1.3623709

Cited by 4 publications

(8 citation statements)

References 11 publications

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“…A reduction in the distance between roll stations to 400 mm slightly reduced the total computational time due to a shorter initial length of the sheet, l = 1000 mm compared to l = 1200 mm. In the previous research of Abrass et al, the computational time was reduced by 55 %. Due to advances in the numerical solvers and computer processing units, the conventional simulation of the complex profile nearly required the same time as that of the U profile.…”

Section: Reduction In the Computational Time By The Sseamentioning

confidence: 95%

“…The basics of extrapolation technique is described in refs. The SSEA generates a new output file containing all extrapolated data. This output file is considered as an initial condition in restarting the conventional simulation. The rolls are moved in longitudinal direction by distance “s” and the conventional simulation is restarted. The process repeats until forming is performed in all stations.…”

Section: Steady State Extrapolation Algorithm (Ssea)mentioning

confidence: 99%

“…The SSEA has been successfully implemented to reduce the computational time in FE analysis of a simple U profile . In this research, experimental investigations are carried out for a complex profile.…”

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

“…Contrary, they could not achieve any reduction in CPU time till this date. A new algorithm developed by Abrass et al accelerates the conventional FE analysis by exploiting steady state properties evolved in roll forming. The developed algorithm generates a stationary zone which allows a better determination of the state variables during the process.…”

Section: Introductionmentioning

confidence: 99%

“…However, large computational cost especially concerning complex profiles has limited the widespread usage of the FE analysis. This study aims at reducing the computational cost of the FE analysis of roll forming of a complex profile by implementing the new algorithm developed by Abrass et al on the conventional FE simulation. For the validation of this algorithm, the numerical results are compared with the experimental outcomes.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties

Mahajan

Abrass

Groche

2018

steel research int.

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Roll forming is a continuous, steady state process where state variables remain unchanged over the process time with respect to a fixed position. The design of roll forming is a complex and iterative process which mainly depends on the experience of designers. In industry, the finite element analysis (FEA) is commonly used to design rolls and to predict important process variables such as longitudinal peak strains and springback. However, the FEA is attributed with a high computational cost. The approach described in this paper aims at the reduction of the computational cost with the aid of steady state properties evolved in roll forming. To exploit the steady state properties, the steady state extrapolation algorithm (SSEA) is used in conjunction with conventional FE simulations. A complex profile requiring 10 roll forming stations is considered for the validation of the simulations. Experimental measurements confirm the results from conventional simulation as well as the simulation assisted by the SSEA. Springback behavior predicted by the simulation using SSEA is also verified successfully. With the help of the SSEA, the total computational time for the FE analysis of the complex profile is reduced by 54.7%.

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Section: Reduction In the Computational Time By The Sseamentioning

confidence: 95%

Section: Steady State Extrapolation Algorithm (Ssea)mentioning

confidence: 99%

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties

Mahajan

Abrass

Groche

2018

steel research int.

Self Cite

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Experimental and Numerical Determination of Roll Forming Loads

Groche

Mueller

Traub

et al. 2013

steel research int.

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Metal forming companies are confronted with increasing customer requirements and qualitative demands. In the course of tighter tolerances and use of harder materials the roll forming process need to be aligned optimally to the profile's specification. Especially in the case of complex cross‐sections the simulation of the forming process is a valuable aid. One challenge of reliable simulations is the consideration of the interaction between sheet metal and tools. Due to their simplification, e.g., missing roll compliance, rigid body models cannot describe the profile – tool interaction sufficiently. This can lead to big differences between experimentally and numerically obtained loads and stresses. Since verification possibilities are unavailable, a consideration of the mill compliance in simulation models has rarely been considered, if at all. This paper shows options to respect the compliance of roll forming mills in simulations. For verification of the load parameters, e.g., contact normal stress, standardized, and new measuring methods are applied.

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