Study On Roll-forming Method And Technique Of High Frequency Welding Rectangular Tube For Automobile Radiator

Welding rectangular tubes were widely used in vehicles, subways, buildings, ships, etc because of its high strength, flexural modulus section, easy to assemble and solid, beauty, and many other irreplaceable advantages. “First round then square” and “directly forming to square” were the two classical forming methods for roll forming of welding rectangular tubes. “First round then square” forming method had fast forming speed and straight welding seam,while quantity of the roll, the high cost of the unit and poor corner forming quality were its main problems. “Directly forming to square” forming method had less forming pass and saved material, while it easily led sidewall to dent and other defects for thin-walled rectangular tube of larger length to width ratio. Therefore,the development of new forming method and technique for thin-walled rectangular tube with larger length to width ratio becomes an significance research topic. The paper proposed the use of sidewall bending compensation method based on the “Directly forming to square” forming method by using numerical simulation and theoretical design. The finite element analysis of dynamic simulation indicated that the method can solve the problem of sidewall depressionIn the paper,the high frequency welding rectangular tube for automobile radiator was research object to further study on sidewall bending compensation method. The process parameters of high frequency welding rectangular tube for automobile radiator design was designed based on roll forming process theoretical design method. The orthogonal test was established by each pass longitudinal strain as quality indicators to get optimum process parameters. The result indicated that the bottom corner bending angle was the main factor affecting the forming quality. Roll pass was designed based on the three-point bending theory. And the importing institution,adjustable racks and forming rolls were designed. The roll forming process of the high frequency welding rectangular tube for automobile radiator was made forming simulation analysis by using ABAQUS finite element analysis software. The result indicated that the forming process were with no depression、warping, wrinkles and other defects,and the stress and strain were reasonable distributed. And the feasibility of sidewall bending compensation method and technique were verified.The result in this paper can provide a scientific and rational reference for practical production.