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

Mahajan, Pushkar and Abrass, Ahmad and Groche, Peter (2018):
FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties.
In: steel research international, WILEY-VCH Verlag, Weinheim, 89, DOI: 10.1002/srin.201700350, [Online-Edition: https://onlinelibrary.wiley.com/doi/full/10.1002/srin.201700...],
[Article]

Abstract

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.

Item Type: Article
Erschienen: 2018
Creators: Mahajan, Pushkar and Abrass, Ahmad and Groche, Peter
Title: FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties
Language: English
Abstract:

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.

Journal or Publication Title: steel research international, WILEY-VCH Verlag, Weinheim
Volume: 89
Divisions: 16 Department of Mechanical Engineering > Institut für Produktionstechnik und Umformmaschinen (PtU)
16 Department of Mechanical Engineering
Date Deposited: 08 May 2018 12:14
DOI: 10.1002/srin.201700350
Official URL: https://onlinelibrary.wiley.com/doi/full/10.1002/srin.201700...
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