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applications:ale:roll-forming

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.

applications/ale/roll-forming.txt · Last modified: 2017/03/10 17:39 by crutzen