P 225 - Determining the bending angle sequence during profiling with elementary calculation approaches

As a result of this research project, a simulation device was developed on the basis of a new forming technology model. This device can be used to compare the contour of the forming zones during roll forming and the stresses on the profile occurring in this zone with good results for the real roll forming process. The starting point for the model developed was the realisation that the dominant factors influencing the quality characteristics of a profile are the longitudinal deformation occurring during the roll forming process. Specific investigations of the longitudinal deformation changes with variations in the bending angle differences for different materials, sheet thicknesses and leg widths yielded important findings for the calculation model. The modelling approach described in the research report makes it possible to determine the longitudinal deformation near the strip edge with simple means and to calculate the bending angle differences after defining limit ranges for the permissible longitudinal deformation. Further ways of including all parameters relevant to the roll forming process in the calculation model were shown. By further refining this model, it may be possible to calculate the quality of a profile, the geometric deviations and macro residual stresses while still in the stage of defining the stage plan. In addition, the research report presents a model for describing the geometry of the moulding zone at the strip edge on the basis of polynomial equations. It is shown that sufficiently accurate results can be achieved with polynomial equations of 7th order and higher with relatively low computational effort. STUDIENGESELLSCHAFT STAHLANWENDUNG e.V.