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====== 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 **
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\\ \\ ** The proposed ALE model of continuous roll forming **
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\\ \\ ** The proposed ALE model of continuous roll forming with post-cutting **
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===== Rocker panel =====
{{ :applications:ale:roll_forming04.png?650 |}}
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** Process parameters **
  * 16 stands – unsymmetrical shape.
  * Material: DP980.
  * Sheet: 6150 x 167 x 1.5 mm
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** Mesh **
  * 2 FE through the thickness.
  * FE length: from 3 mm to 15 mm
  * 73 226 FE.
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\\ \\ ** ALE roll forming with welding and post-cutting **
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===== Symmetrical C-channel =====
\\ ** Classical transient Lagrangian model **
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** Process parameters **
  * 14 stands – symmetrical shape.
  * Material: DP980.
  * Sheet: 910 x 300 x 1.25 mm
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** Mesh **
  * 2 FE through the thickness.
  * FE length: 3 mm.
  * 22 940 FE.
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\\ \\ ** The proposed ALE model of continuous roll forming **
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** Process parameters **
  * 14 stands – symmetrical shape.
  * Material: DP980.
  * Sheet: 4640 x 300 x 1.25 mm
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** Mesh **
  * 2 FE through the thickness.
  * FE length: from 3 mm to 15 mm
  * 39 600 FE.
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===== Symmetrical tube =====
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** Process parameters **
  * 24 stands – symmetrical shape.
  * Material: DP980.
  * Sheet: 7770 x 159 x 1 mm
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** Mesh **
  * 2 FE through the thickness.
  * FE length: from 3 mm to 8 mm
  * 68 640 FE.
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