Research On Process Of Integral Forming Of Container Roof Plate

At present studies, the forming process of the container roof with five long embossing is the drawing process. The traditional processing technology cuts sheet according to the blank length firstly, and then draws one by one, finally prunes the size of the roof trim edges. As the container top plate production technology developing, and because of the low productivity of traditional technology, this paper presents that using continuous sheet to form five embossing in one-time die, then cutting the sheet according to the length of the roof. New technology greatly improves efficiency, saves materials, and reduces cost. But because of various reasons,such as the obvious shallow depth of wave, ambiguous edges and severe thickness reduction,some customers don’t accept the product.Aiming for those problems, this paper presents the research of integrally formed process of container roof. Through the finite element numerical simulation, optimization of the overall forming process has been achieved. Experiments and verification also have been done to provide theoretical and experimental data of integrally formed process of container roof for comprehensive promotion. The studies content and conclusions of this paper are as follows:1. The whole roof forming process was analyzed concretely, including the characteristics of the roof overall forming, CORTEN steel material properties, the product defects caused by existing process, and the impact of the drawing die for roof forming.2. The whole roof springback characteristic in forming was analyzed, especially influence of forming technology parameters in the intensive rounded corners, drawbead height and blank-holder force in whole roof forming are discussed in this paper, and designed the concrete research plan.3. The paper introduced the roof overall forming process on the modeling of finite element simulation and analysis in detail, and obtained the corresponding simulation results according to the research plan designed by simulation. Through the comparative analysis of forming limit, thickness distribution, major stress distribution and edge movement distribution of the roof forming process under different parameters, optimized process parameters has been confirmed as below: intensive rounded corners for R1 = 12 mm, R2 = 12mm; drawbead reinforced height for 5 mm; and the blank-holder force for 550 ton. To optimize the process parameters of actual test inspection, obtained the roof with better forming quality and depth of 24 mm which satisfied customer’s requirements. And compared to the roof with the depth commonly for 21 mm before optimized, the new roof has been improved largely.