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In roll forming, the planning of the forming stage sequence as well as the tool design is still essentially based on empirically acquired employee knowledge. One reason for this is the medium-sized structure of many …
In roll forming, the planning of the forming stage sequence as well as the tool design is still essentially based on empirically acquired employee knowledge. One reason for this is the medium-sized structure of many roll forming companies, which shy away from the cost-intensive preliminary work for a simulation workstation. Another reason is the sequence of complicated three-dimensional stress and deformation states with a large number of influencing parameters which make it difficult to create a suitable calculation model. The aim of this research project was to improve the software and reduce the effort required for practical application.
Based on an earlier research project, the existing calculation model for the roll forming process was further developed. The main aim here was to shorten the computing time and optimise the simulation options. At the centre of the investigations was a sensitivity analysis of essential process parameters from the influences of the tool system and the material parameters. The results were transferred to the calculation model. By using shell elements to represent a sheet metal segment and by modifying the tool movement, the required calculation time could be reduced to a quarter of the original time. The sensitivity analysis allowed a significant addition to the previously incomplete process knowledge and the adapted consideration of the influence of different parameters for influencing the forming result. In practice, the research work will lead to an improvement in the preliminary design of the tools and the sequence of stages. In conjunction with the reduction in the number of optimisation stages, this will result in a significant shortening of the preparation phase for actual production. It is to be expected that smaller and medium-sized companies in particular will benefit from this simplified numerical process simulation and its introduction into operational practice. STUDIENGESELLSCHAFT STAHLANWENDUNG e.V.
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