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applications:ale:roll-forming

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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.


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

<html> <iframe width=“560” height=“200” src=“www.youtube.com/embed/YFefQOfrAs4” frameborder=“0” allowfullscreen></iframe> </html> </WRAP>

The proposed ALE model of continuous roll forming

<html> <iframe width=“560” height=“200” src=“www.youtube.com/embed/2v0BybZ6RDU” frameborder=“0” allowfullscreen></iframe> </html> </WRAP> —- ===== Rocker pannel =====

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 3mm to 15mm
  • 73 226 FE.

<html> <iframe width=“853” height=“480” src=“https://www.youtube.com/embed/ErGFDPBwErk?rel=0” frameborder=“0” allowfullscreen></iframe> </html>

<html> <iframe width=“853” height=“480” src=“https://www.youtube.com/embed/GCJ45lAsiww?rel=0” frameborder=“0” allowfullscreen></iframe> </html>

—- ===== Symmetrical C-channel =====

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 3mm to 15mm
  • 39 600 FE.

<html> <iframe width=“853” height=“480” src=“https://www.youtube.com/embed/r50YtdWGqxA?rel=0” frameborder=“0” allowfullscreen></iframe> </html>

applications/ale/roll-forming.1445592742.txt.gz · Last modified: 2016/03/30 15:22 (external edit)

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