P 219 - Development and testing of a process simulation model for process-specific CAD step sequence planning in roll forming

However, planning errors can currently only be detected after the tools have been manufactured and installed in the roll forming machine. This results in considerable costs due to long setting times and possibly necessary tool changes, which can jeopardise the economic efficiency of the process. As part of this project, a programme module, the so-called technology processor, was developed which makes it possible to generate a finite element analysis (FEM) of the roll forming process from the data of the CAE system and to evaluate the results. The planning process with the aid of the technology processor in the CAE system conventionally begins with the definition of the final profile cross-section, the determination of the sequence of forming stages and the design of the individual forming rolls. The geometric and technological data of the roll forming process defined in this way is transferred to the technology processor. This creates the required input data for the FEM simulation largely automatically, starts the calculation and then analyses the calculation result. Planning errors can thus be detected and rectified at an early stage with the help of numerical simulation. In this way, considerable costs can be saved by avoiding mould reworking. In addition, production time is gained through shorter planning and setting times. Computer-aided planning systems in conjunction with the technology processor allow cold profile manufacturers - generally small and medium-sized companies - to produce without relying solely on employee expertise and to process orders more quickly and with less susceptibility to faults. The rights to the programme module developed as part of this project are held by Studiengesellschaft Stahlanwendung e.V. and are available on request. STUDIENGESELLSCHAFT STAHLANWENDUNG e.V.