Computer Aided Hole Design And Simulation Of Forming Numerical Simulation In Cold Forming Of Column Plate

A roll forming line includes a number of rolls, each roll pass parameters are calculated complex and repeatly. Shan xi Ding rong Cold-Formed Steel Ltd calculates the pass parameters based on the experience, then draw the roll flower patterns by CAD. This calculation method has low efficiency, error-prone, and the designed roll model had been verified by actual production. With the development of computer, using computer technology to be roll pass-aided design and finite element simulation of forming process has become a trend.The present work investigates the cold roll forming of a symmetrical column section. The total roll passes are calculated according to the theory and experience formula. Based on the fixed radius forming method and the bending angle distribution experience formula, the computer aided software is compiled by using Visual Basic 6.0(VB) programming system. The bending angles of the cold roll forming and the width parameters on internal and external sides. In addition, the compiled software redevelops the SolidWorks. The roll flower patterns are automatically generated based on the roll pass parameters calculated by the software. The roll flower patterns are employed for 3D model in finite element analysis by ABAQUS software. Then the cold forming process of the column section is simulated after the analysis steps, boundary conditions and contacts are provided. The simulation results show that the maximum and relatively large stresses occur at the positions where the rollers and plates contact. The edge plastic strain(PEEQ) is larger than 0, indicating occurrence of yielding, which is consistent with the experimental results. The stresses in nephogram of Y(S22) have positive and negative values, implying that some parts of the plate are under tension, the others are under compression. This leads to obvious bending in the front and end parts of plate. Three nodes are selected during the simulation to compare the simulated stresses and energies with experimental values. Because the total roll pass during simulation decrease, the total energy consumption reduces meanwhile the max stresses have not increase. Then, the forming defects are analyzed and the improvement schemes are given. The strain curves of the same node after simulations by changing the roller gap from 800 mm to 1000 mm indicate that the longitudinal bending degree reduces due to the increase of the roll spacing. The springback values of sheet can be reduced by over bending an angle. Finally, the cross-sectional shape of the column after the simulation compared with the actual shape, the maximum deviation is 1.04 mm less than 3mm, it meets the project needs.