Lagrangian and arbitrary Lagrangian Eulerian simulations of complex roll-forming processes

Crutzen, Yanick; Boman, Romain; Papeleux, Luc; Ponthot, Jean‐Philippe

doi:10.1016/j.crme.2016.02.005

Cited by 19 publications

(24 citation statements)

References 20 publications

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“…An isotropic power‐law hardening rule is described as

σ_{f} = K \times {(ϵ_{p})}^{n}

, where σ f is the flow stress, K is the strength coefficient, ϵ p is the plastic strain, and n is the strain hardening coefficient. Non‐linear kinematic hardening is neglected as no plastic unbending occurs during the forming . In simulations, the contact is established by a node‐to‐segment contact algorithm .…”

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

“…The interference of the deformations can influence the outcome of the process. According to Table , only Crutzen et al investigated a roll forming process with this property.…”

Section: Introductionmentioning

confidence: 99%

“…All studies mentioned before used the classical Lagrangian formulation to obtain a stationary solution. The Arbitrary Lagrangian formulation (ALE) formulation has also been used successfully for roll forming of a simple U and a complex rocker panel . Eulerian step in ALE formulations requires 77% of global wall‐clock time as stated by Crutzen et al They believe that if the Eulerian step is computed parallel with multiple processors, a huge reduction in total CPU time is possible compared to the Lagrangian simulation with the same number of finite elements.…”

Section: Introductionmentioning

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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“…An isotropic power‐law hardening rule is described as

σ_{f} = K \times {(ϵ_{p})}^{n}

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

“…The interference of the deformations can influence the outcome of the process. According to Table , only Crutzen et al investigated a roll forming process with this property.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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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“…The numerical simulations non-Newtonian fluid flow in three dimensional moulding process were performed with ALE method and the capabilities of this method were demonstrated by Wang and Li [37]. ALE formulations was used for the numerical simulation of a complex continuoustype roll-forming process using the in-house finite element code METAFOR and results were in good agreement with classical Lagrange method [38]. Recently, the manufacturing chain including the continuous roll-forming operation, the in-line welding process for closed sections and the post-cut operations was numerically simulated with ALE method by Crutzen et al [39].…”

Section: Introductionmentioning

confidence: 96%

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

Topa¹,

Cerik²,

Kim³

2020

Preprint

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The development of numerical simulations is potentially useful in predicting the most suitable manufacturing process and ultimately improving product quality. Seamless pipes are manufactured by rotary piercing process in which round bars are fed between two rolls and pierced by a stationary plug. During this process, the material undergoes severe deformation which renders it impractical to be modelled and analysed with conventional finite element methods. In this paper, three dimensional numerical simulations of the piercing process are performed with Arbitrary Lagrangian-Eulerian (ALE) Formulation in LS DYNA software. Details about the material model as well as the elements formulations are elaborated here and mesh sensitivity analysis was performed. The results of the numerical simulations are in good agreement with experimental data found in the literature and the validity of the analysis method is confirmed. The effects of varying workpiece velocity, process temperature, and wall thickness on the maximum stress levels of the product material/pipes are investigated by performing simulations of sixty scenarios. Three dimensional surface plots are generated which can be utilized to predict the maximum stress value at any given combination of the three parameters.

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“…The numerical simulations of non-Newtonian fluid flow in a three-dimensional moulding process were performed with the ALE method and the capabilities of this method were demonstrated by Wang and Li [37]. ALE formulations were used for the numerical simulation of a complex continuous-type roll-forming process using the in-house finite element code METAFOR and results were in good agreement with the classical Lagrange method [38]. Recently, the manufacturing chain, including the continuous roll-forming operation, the in-line welding process for closed sections, and the post-cut functions, was numerically simulated with the ALE method by Crutzen et al [39].…”

Section: Introductionmentioning

confidence: 99%

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

Topa

Cerik

Kim

2020

JMSE

View full text Add to dashboard Cite

The development of numerical simulations is potentially useful in predicting the most suitable manufacturing processes and ultimately improving product quality. Seamless pipes are manufactured by a rotary piercing process in which round billets (workpiece) are fed between two rolls and pierced by a stationary plug. During this process, the material undergoes severe deformation which renders it impractical to be modelled and analysed with conventional finite element methods. In this paper, three-dimensional numerical simulations of the piercing process are performed with an arbitrary Lagrangian–Eulerian (ALE) formulation in LS-DYNA software. Details about the material model as well as the elements’ formulations are elaborated here, and mesh sensitivity analysis was performed. The results of the numerical simulations are in good agreement with experimental data found in the literature and the validity of the analysis method is confirmed. The effects of varying workpiece velocity, process temperature, and wall thickness on the maximum stress levels of the product material/pipes are investigated by performing simulations of sixty scenarios. Three-dimensional surface plots are generated which can be utilized to predict the maximum stress value at any given combination of the three parameters.

show abstract

Lagrangian and arbitrary Lagrangian Eulerian simulations of complex roll-forming processes

Cited by 19 publications

References 20 publications

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

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

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

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