Geometrical accuracy improvement in flexible roll forming lines

Larrañaga, Jon; Berner, Sebastian; Galdos, Lander; Groche, Peter

doi:10.1063/1.3552505

Cited by 21 publications

(8 citation statements)

References 4 publications

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“…To ensure proper temperature pattern measurement with the thermographic camera, plates are painted with a black colour high temperature-resistant paint in which temperature-dependent emissivity is already determined [56]. However, for better accuracy, the temperature acquisition data of the thermocouples is used to calibrate the acquired temperature pattern.…”

Section: Temperature Pattern Measurementmentioning

confidence: 99%

Residual Stress Pattern Prediction in Spray Transfer Multipass Welding by Means of Numerical Simulation

Esnaola¹,

Ulacia²,

Lopez-Jauregi³

et al. 2018

Residual Stress Analysis on Welded Joints by Means of Numerical Simulation and Experiments

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One of the main problems of gas metal arc welding (GMAW) process is the generation of residual stresses (RS), which has a direct impact on the mechanical performance of welded components. Nevertheless, RS pattern prediction is complex and requires the simulation of the welding process. Consequently, most of the currently used dimensioning approaches do not consider RS, leading to design oversized structures. This fact is especially relevant in big structures since it generates high material, manufacturing and product transportation costs. Nowadays, there are different numerical methods to predict the RS generated in GMAW process, being Goldak's method one of the most widely used model. However, the use of these methods during the design process is limited, as they require experimentally defining many parameters. Alternatively, in this chapter, a new methodology to define the heat source energy based on the spray welding physics is exposed. The experimental validation of the methodology conducted for a multipass butt weld case shows good agreement in both the temperature pattern (9.16% deviation) and the RS pattern (42 MPa deviation). Finally, the proposed methodology is extended to analyse the influence of the thickness and the number of passes in the RS pattern of thick T-joint welds.

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Section: Temperature Pattern Measurementmentioning

confidence: 99%

Residual Stress Pattern Prediction in Spray Transfer Multipass Welding by Means of Numerical Simulation

Esnaola¹,

Ulacia²,

Lopez-Jauregi³

et al. 2018

Residual Stress Analysis on Welded Joints by Means of Numerical Simulation and Experiments

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show abstract

“…The stainless steel much less springback because more tension release more than other materials. 4. In a general conclusion, with increasing thickness and increasing yeild strength the springback in different bend angles was decreased.…”

Section: Discussionmentioning

confidence: 79%

“…Groche and et.al introduced the FRF process as a method for the production of high strength steels components used in the car body [3]. Larenga and Galdos for investigation of the web waring, applied local heating during FRF, most local heating effect is achieved when before the start of forming, the wings of the whole area should be heated [4]. Kasaei and et.al studied wrinkling on the transition zone using finite element analysis, according to the results of the study, wrinkling occurs when the longitudinal compressive strain is less than the required compressive strain calculated by mathematical modeling to obtain geometry considered in the transition zone [5].…”

Section: Fig 2 the Verticality Of Rollers In Different Positions On The Bending Curvementioning

confidence: 99%

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Panahizadeh

Asl

Saeedi

et al. 2021

Preprint

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The Flexible Roll Forming (FRF) process with the ability to produce parts with variable width and depth was formed to be used in industries such as automotive, construction, and similar industries. One of the disadvantages of this process is the spring-back defect, which prevents the desired profile from being achieved. In this paper, experimental and numerical analysis of the spring-back phenomenon using Hill, Barlat, and Von Mises yield criteria. Also, the effect of bending angle, material, and sheet thickness parameters on this defect was investigated. The process for the three types of 1050 aluminum, low carbon steel, and 430 stainless steel was simulated using the VUMAT subroutine of Abaqus software. In these simulations, for each material, three thicknesses of 0.4, 0.7 and 1 mm with bending angles of 25 and 45 degrees were considered. Experimental experiments were performed using the FRF machine. Validation of numerical simulation results was performed by comparing experimental results. The results showed that the Barlat criterion has a more accurate prediction of spring-back than the other two criteria. The results also showed that the spring-back ratio of sheets with a thickness of 0.4 mm compared to 1 mm for low carbon, aluminum, and stainless steel are 1.5, 2.5, and 3.2, respectively.

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“…8 a) and a Titanium DC019U-E thermographic camera is used to record surface temperature pattern. Plates are painted with a high temperature resistant black colour paint which temperature dependent emissivity is already determined [53]. However, for better accuracy, acquired temperature pattern is calibrated with thermocouples acquisition data.…”

Section: A) B)mentioning

confidence: 99%

Procedure to predict residual stress pattern in spray transfer multipass welding

Lopez-Jauregi

Ulacia

Esnaola

et al. 2014

Int J Adv Manuf Technol

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Gas metal arc welding (GMAW) is one of the most used joining method in the industry.However, one of the main problems of this process is the generation of residual stresses which have direct impact on the fatigue life of welded components. Nevertheless, residual stress pattern prediction is complex and requires the simulation of the welding process. Currently, there are different numerical methods to predict the residual stresses generated in GMAW process, being Goldak's method one of the most widely used model. However, the main limitation of these methods is that they require defining many parameters experimentally and consequently this method is not valid during design process.Alternatively, in this work, it is developed a procedure where the heat source is defined based on the welding physics for spray transfer welding. The developed procedure has been validated for a spray transfer multipass butt weld case. Results have shown good correspondence with an average deviation of 9.16% in thermal field and 42 MPa in the final residual stress field. Thus, the developed procedure has been validated as a cost effective alternative method to estimate residual stress pattern in spray transfer multipass welding. Furthermore, the developed method does not require any welding experimental characterization once the efficiency of the used welding machine is defined. The proposed method can be used as a valid tool to optimize the welding process in order to minimize the residual stress field and, consequently, improve the fatigue life.

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Geometrical accuracy improvement in flexible roll forming lines

Cited by 21 publications

References 4 publications

Residual Stress Pattern Prediction in Spray Transfer Multipass Welding by Means of Numerical Simulation

Residual Stress Pattern Prediction in Spray Transfer Multipass Welding by Means of Numerical Simulation

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Procedure to predict residual stress pattern in spray transfer multipass welding

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