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Experimental and numerical investigation of the bending zone in roll forming

Traub, Tilman and Chen, Xin and Groche, Peter (2017):
Experimental and numerical investigation of the bending zone in roll forming.
In: International Journal of Mechanical Sciences, pp. 956-970, 131-132, [Article]

Abstract

Roll forming is a widespread method for manufacturing cold rolled profiles. Increasing requirements regarding tolerances challenge existing procedures for designing roll forming processes. For instance, despite a large number of calculation methods, a reliable prediction of the initial sheet width has not been possible yet. The initial sheet width is crucial for the product quality since this dimension influences the lengths of the legs of the profile directly and thus the tolerances being achievable. Furthermore, with respect to the thickness reduction of profiles due to lightweight design and the use of high strength steels, the reliable prediction of the additional thinning of the profile during the roll forming process in the bending zones is gaining more and more importance. Presently, there is no feasible approach providing detailed information on the strain distribution and thus the thickness reduction in the bending zone during roll forming processes without significantly delaying the planning process. Therefore, this study presents a numerical modelling approach combining global and submodels enabling a high resolution of the strain distribution in the bending zone at acceptable computational costs. The application of the validated numerical model proves in good accordance with experimental results that the profile geometry (U-channel versus C-profile) and the bending ratio (bending radius divided by sheet thickness) are the main factors of influence on the strain distribution in the bending zone.

Item Type: Article
Erschienen: 2017
Creators: Traub, Tilman and Chen, Xin and Groche, Peter
Title: Experimental and numerical investigation of the bending zone in roll forming
Language: English
Abstract:

Roll forming is a widespread method for manufacturing cold rolled profiles. Increasing requirements regarding tolerances challenge existing procedures for designing roll forming processes. For instance, despite a large number of calculation methods, a reliable prediction of the initial sheet width has not been possible yet. The initial sheet width is crucial for the product quality since this dimension influences the lengths of the legs of the profile directly and thus the tolerances being achievable. Furthermore, with respect to the thickness reduction of profiles due to lightweight design and the use of high strength steels, the reliable prediction of the additional thinning of the profile during the roll forming process in the bending zones is gaining more and more importance. Presently, there is no feasible approach providing detailed information on the strain distribution and thus the thickness reduction in the bending zone during roll forming processes without significantly delaying the planning process. Therefore, this study presents a numerical modelling approach combining global and submodels enabling a high resolution of the strain distribution in the bending zone at acceptable computational costs. The application of the validated numerical model proves in good accordance with experimental results that the profile geometry (U-channel versus C-profile) and the bending ratio (bending radius divided by sheet thickness) are the main factors of influence on the strain distribution in the bending zone.

Journal or Publication Title: International Journal of Mechanical Sciences
Volume: 131-132
Uncontrolled Keywords: Roll forming; Simulation; Strain distribution
Divisions: 16 Department of Mechanical Engineering > Institut für Produktionstechnik und Umformmaschinen (PtU)
16 Department of Mechanical Engineering
Date Deposited: 21 Aug 2017 06:33
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