~~NOTOC~~ ====== Roll forming ====== A metal strip is incrementally bent by sets of rolls (called “forming stands”) until the desired cross section is obtained. {{ :applications:ale:roll_forming01.png?600 |}} ---- {{ :applications:ale:roll_forming02.png?200|}} ===== Symmetrical U-channel ===== ** Process parameters ** * Experimental mill (ArcelorMittal R&D, Montataire, France). * 6 stands (15°, 32°, 50°, 68°, 80°, 90°). * Final bending radii: 6 mm * Inter-stand distance: 0.5 m * Sheet: 2000 x 200 x 1.6 mm * Sheet velocity: v = 200 mm/s {{ :applications:ale:roll_forming03.png?200|}} * Coulomb friction $\mu$ = 0.2 * DP980 steel (sY0 = 697.34 MPa). ** Numerical parameters ** * Symmetry. * Friction drives the sheet. * Two layers of EAS elements. * Dynamic implicit scheme (Chung-Hulbert). \\ \\ ** Classical transient Lagrangian model ** {{url>//www.youtube.com/embed/YFefQOfrAs4 560px,315px noborder fullscreen}} \\ \\ ** The proposed ALE model of continuous roll forming ** {{url>//www.youtube.com/embed/2v0BybZ6RDU 560px,315px noborder fullscreen}} \\ \\ ** The proposed ALE model of continuous roll forming with post-cutting ** {{url>https://www.youtube.com/embed/1rEJP7A6J6k?ecver=1 560px,315px noborder fullscreen}} ---- ===== Rocker panel ===== {{ :applications:ale:roll_forming04.png?650 |}} ** Process parameters ** * 16 stands – unsymmetrical shape. * Material: DP980. * Sheet: 6150 x 167 x 1.5 mm ** Mesh ** * 2 FE through the thickness. * FE length: from 3 mm to 15 mm * 73 226 FE. {{url>https://www.youtube.com/embed/ErGFDPBwErk?rel=0 560px,315px noborder fullscreen}} {{url>https://www.youtube.com/embed/GCJ45lAsiww?rel=0 560px,315px noborder fullscreen}} \\ \\ ** ALE roll forming with welding and post-cutting ** {{url>https://www.youtube.com/embed/S93UXLJjxYk?ecver=1 560px,315px noborder fullscreen}} ---- ===== Symmetrical C-channel ===== \\ ** Classical transient Lagrangian model ** ** Process parameters ** * 14 stands – symmetrical shape. * Material: DP980. * Sheet: 910 x 300 x 1.25 mm ** Mesh ** * 2 FE through the thickness. * FE length: 3 mm. * 22 940 FE. {{url>https://www.youtube.com/embed/uz9UjHquEF4 560px,315px noborder fullscreen}} \\ \\ ** The proposed ALE model of continuous roll forming ** ** Process parameters ** * 14 stands – symmetrical shape. * Material: DP980. * Sheet: 4640 x 300 x 1.25 mm ** Mesh ** * 2 FE through the thickness. * FE length: from 3 mm to 15 mm * 39 600 FE. {{url>https://www.youtube.com/embed/r50YtdWGqxA?rel=0 560px,315px noborder fullscreen}} ---- ===== Symmetrical tube ===== ** Process parameters ** * 24 stands – symmetrical shape. * Material: DP980. * Sheet: 7770 x 159 x 1 mm ** Mesh ** * 2 FE through the thickness. * FE length: from 3 mm to 8 mm * 68 640 FE. {{url>https://www.youtube.com/embed/KlCzLpHCa7o?ecver=1 560px,315px noborder fullscreen}}