Design And Analysis On Roll Forming Of Vehicle Corrugated Plate And Tailor Rolled Tube

Today, the automotive industry is facing a huge challenge from the energy, environment, safety and comfort, automotive lightweight technology comes into being. High-strength steel and tailor rolled blanks play an important role in the field of automotive lightweight. As the important forming way in the automobile parts production, more and more applications of roll forming in the field of high-strength steel and tailor rolled blank are applied.In this paper, high-strength steel corrugated plate and tailor rolled tube are researched by the methods of numerical simulation. The roller passes aiming at two kinds of roll forming products are designed to acquire quality products, Then simulations of three roll forming schemes for high-strength steel corrugated plate and tailor rolled tube are studied by ABAQUS/Explicit, the three dimensional elastoplasticity finite element model of the corrugated plate is established, It is related to the problems about constructing models, choosing element, boundary condition, virtual speed and mass scaling factor, in addition, the numerical simulation is evaluated useful. The conclusions are as follows:(1) There appears edge wave phenomenon in the corrugated plate edge with eight roll passes after forming, as the forming pass increases to twelve passes, the edge wave phenomenon is disappeared. Size accuracy of product is assured, it proves the roll pass of twelve passes is the best scheme.(2) Simulation for roll forming process of high-strength steel corrugated plate with twelve roll passes is conducted, equivalent stress, strain and the distribution rule in the different forming stage of corrugated plate are obtained, and it proves the corrugated plate forming is mainly a result of the transverse forming. The effect of roll pass parameters and springback to forming results is explored.(3) The forming precision of three schemes for tailor rolled tube after roll forming is compared, it is proved scheme one (without horizontal rollers) is the best scheme. The analysis also shows that deforming effect should be comprehensively considered to decide whether to add horizontal rollers in the designing process.(4) Simulation for roll forming process of scheme one for tailor rolled tube is conducted, equivalent stress, strain and deformation law in the different forming stage of tailor rolled tube are obtained, roll forming process of the equal thickness tube is researched, two different forming types are compared. It indicates the transition zone of thickness exists stress concentration for tailor rolled tube during the roll forming process.The above analysis and results for the high-strength steel corrugated plate and tailor rolled tube have certain guiding significance and valuable reference in the actual production.