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Experimental and numerical investigation of the bending zone in roll forming

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

Kurzbeschreibung (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.

Typ des Eintrags: Artikel
Erschienen: 2017
Autor(en): Traub, Tilman ; Chen, Xin ; Groche, Peter
Titel: Experimental and numerical investigation of the bending zone in roll forming
Sprache: Englisch
Kurzbeschreibung (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.

Titel der Zeitschrift, Zeitung oder Schriftenreihe: International Journal of Mechanical Sciences
Band: 131-132
Freie Schlagworte: Roll forming; Simulation; Strain distribution
Fachbereich(e)/-gebiet(e): 16 Fachbereich Maschinenbau > Institut für Produktionstechnik und Umformmaschinen (PtU)
16 Fachbereich Maschinenbau
Hinterlegungsdatum: 21 Aug 2017 06:33
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