Development and verification of a one-step-model for the design of flexible roll formed parts

Groche, Peter; Zettler, A.; Berner, Sebastian; Schneider, Georg

doi:10.1007/s12289-010-0998-3

Cited by 67 publications

(41 citation statements)

References 7 publications

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“…Most of the material motion in roll forming is a rigid motion except the material motion in the deformation zone. Contrary to roll forming, velocity fields during flexible roll forming of continuously varying cross‐sections can change during the process …”

Section: Steady State Extrapolation Algorithm (Ssea)mentioning

confidence: 99%

“…Contrary to roll forming, velocity fields during flexible roll forming of continuously varying cross-sections can change during the process. [28] Computational time (hours) [12] (1996) U 3 600 mm, 1034, solid element (8 node) 400 250 [9] (1998) U 3 1200 mm, 3960, shell element (4 node) 146 2.5 [13] (2005) U 6 1000 mm, 2750, solid shell (8 node) 330 34 [14] (2008) U 5 950 mm, 3840, solid shell (8 node) 450 17 [15] (2009) U 6 4000 mm, not specified, Hex 8 (ALE) 500 41 4000 mm, not specified, Hex 8 (Lagrangian) 10 [16] (2009) U 5 2000 mm, 17 000, solid element (8 node) 500 60 [17] (2011) U 6 1300 mm, not specified, solid element (8 node) 500 12 [18] (2012) V 5 2000 mm, 9450, solid shell (8 node) 305 6.1 [19] (2013) Asym-metric U 8 1020 mm, 17 163, solid element (8 node) 400 21 3320 mm, 55 776, solid element (8 node) 21 [20]…”

Section: Steady State Metal Forming Processesmentioning

confidence: 99%

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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: Steady State Extrapolation Algorithm (Ssea)mentioning

confidence: 99%

Section: Steady State Metal Forming Processesmentioning

confidence: 99%

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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“…In later research projects modifications of the standard roll forming simulation were created. Zettler and coworkers determined a “one‐step‐model,” which supported the design of flexible roll forming parts in a numerical simulation. Goertan et al investigated the bending of branched profiles in finite element simulation.…”

Section: State Of the Artmentioning

confidence: 99%

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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“…A particular tooling system with movable forming rolls enables this. If these exceed a certain level the profiles flange bulges [4,5]. Since a perpendicular roll gap on the band edge is essentially for the realization of profiles in close tolerances, the tool movement needs to contain a rotatory and a translatory degree of freedom.…”

Section: Introduction On Flexible Roll Formingmentioning

confidence: 99%