Roll forming
A metal strip is incrementally bent by sets of rolls (called “forming stands”) until the desired cross section is obtained.
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
- 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
The proposed ALE model of continuous roll forming
The proposed ALE model of continuous roll forming with post-cutting
Rocker panel
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.
ALE roll forming with welding and post-cutting
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.
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.
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.