The Element Analysis Research Of The Variable Height Roll-die Forming Process

The roll-die forming of variable height roll forming process is a new plastic forming process of hybrid rolls and the forming mold, by the combination of a fixed forming mold and movable rolls which drove by a servo motor to forming the sheets into the height variable cross-section part.In the paper, the process research of the roll forming in variable height roll-die forming by the dynamics explicit finite element dynamic arithmetic based on the ABAQUS/Explicit solver to do the whole process of double precision finite element simulation.By extracting the values of the equivalent stress, the equivalent plastic strain and the section thickness of the sheet from forming simulation results, to extract the forming deformation of DP980 sheet, obtained the roll forming force variation and forecast the situation of section rebound after the forming.It has determined the feasibility and the best forming process for The roll-die forming of variable height roll forming process in this paper, by comparing the sheet status, the forming force of the rollers and the redundancy deformations after the simulation of 28 kinds of models, which in different pitch passes, different release gap, with or without auxiliary rolls. It has provide a reliable theoretical basis and optimization program for the manufacture of the roll forming of variable height roll-die forming machine. Model settings are as follows:1. after comparing five pitch passes in 320mm,380mm,440mm,500mm, 560mm of the models, shows that:the best forming passes pitch was certain and determined near optimal three passes pitches;2. after comparing of 0,0.05mm,0.1mm,0.15mm four single-sided release gap between the sheet and the rollers, corresponding to the three kinds of the passes pitch, shows that:suitable release gap could reduce the forming force of the rollers, and selected three outstanding models for the after simulations;3. after set six passes auxiliary rolls for the four outstanding models to comparing the simulation of without auxiliary rolls models, shows that:the addition of auxiliary rollers helped to reduce the redundancy deformations of longitudinal bending after the forming;This paper demonstrate the feasibility of The roll-die forming of variable height roll forming process by sufficiently comprehensive in-depth study, and provide a reliable theory and optimization for the development roll forming of variable height roll-die forming machine.