~~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 |}}
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{{ :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}}
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===== 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}}
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===== 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}}
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===== 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}}