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Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm

Abrass, Ahmad and Groche, Peter and Kessler, Thomas (2012):
Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm.
In: Key Engineering Materials, Trans Tech Publications, Switzerland, pp. 857-862, 504, (504-506), [Article]

Abstract

For the manufacturing of large quantities of profile-shaped products, the roll forming process represents one of the most effective metal forming technologies. During this process, the sheet metal will be formed into a desired cross-sectional profile using successive pairs of forming rolls. This process is well known as a very complex process in industry because of the multiplicity of the process and design parameters. For that reason, the optimization of roll forming processes using numerical methods like the finite element method is very complex and time-consuming. In this paper, a numerical method will be introduced to accelerate the simulation and to optimize the roll forming process. The newly developed algorithm will be illustrated and validated by analyzing the roll forming process. The details of the FE-model and the numerical algorithm will be described. Furthermore, the results of the numerical simulation with and without the application of the numerical algorithms will be compared. Finally, the process will be optimized using the newly developed method.

Item Type: Article
Erschienen: 2012
Creators: Abrass, Ahmad and Groche, Peter and Kessler, Thomas
Title: Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm
Language: English
Abstract:

For the manufacturing of large quantities of profile-shaped products, the roll forming process represents one of the most effective metal forming technologies. During this process, the sheet metal will be formed into a desired cross-sectional profile using successive pairs of forming rolls. This process is well known as a very complex process in industry because of the multiplicity of the process and design parameters. For that reason, the optimization of roll forming processes using numerical methods like the finite element method is very complex and time-consuming. In this paper, a numerical method will be introduced to accelerate the simulation and to optimize the roll forming process. The newly developed algorithm will be illustrated and validated by analyzing the roll forming process. The details of the FE-model and the numerical algorithm will be described. Furthermore, the results of the numerical simulation with and without the application of the numerical algorithms will be compared. Finally, the process will be optimized using the newly developed method.

Journal or Publication Title: Key Engineering Materials, Trans Tech Publications, Switzerland
Volume: 504
Number: 504-506
Uncontrolled Keywords: Cold Roll Forming, Finite Element Method, Steady state extrapolation algorithm
Divisions: 16 Department of Mechanical Engineering
16 Department of Mechanical Engineering > Institut für Produktionstechnik und Umformmaschinen (PtU)
Date Deposited: 02 Aug 2012 06:41
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