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The forming process in roll forming for the production of bar-shaped cold-formed profiles is extremely complex and has not yet been fully analysed theoretically. Machines and tool design are still largely based on the …
P 216 - Further development of a measuring method to determine technological parameters for a CAD system by analysing deformation in the forming zone surfaces of roll-formed cold profiles The forming process in roll forming for the production of bar-shaped cold-formed profiles is extremely complex and has not yet been fully analysed theoretically. Machines and tool design are still largely based on the experience of employees in roll forming companies. In order to be able to plan the profiling step sequence and tool geometry better, faster and more independently of the experience of individual employees in the future, precise knowledge of the forming process is required.
As part of this research project, a new method was developed with which the forming zone can be mapped and analysed as a mathematical model. The basis for this is the mapping of the moulding zone geometry as a free-formed surface. This opens up the possibility of calculating elongations, curvatures and also surface information based on a consistent database. With the help of a point grid applied to the sheet before forming and an analysis of the distortions after the profiling process, it was possible to determine local geometry and deformation values for different profiling parameters such as angle step sequence, sheet thickness and leg length. A new instrument for analysing deformation was developed with the method for mathematically mapping the forming zone geometry as a free-formed surface. It offers a good tool for a possible future simulation of the roll forming process, with which a sufficiently good mapping of the deformation process can be achieved. In the future, a sophisticated simulation technique will provide the designer with an instrument that can also be used to calculate new profile geometries and optimise step sequence planning.
Machine-translated title and description. The document itself is in German.
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