Research On Roll Forming Mechanism Based On Finite Element Analysis

In the roll forming process,the sheet undergoes multiple loading,unloading,and reloading.In many cases,the reverse loading process is involved.The history of strain and stress is extremely complicated,and it is urgent to consider the Bauschinger effect of the material.In this roll forming application,there are happens sometimes forming defects such as longitudinal bending,torsion,side waves,and uneven thinning,which seriously affect the product quality.Therefore,the study of roll forming deformation mechanism based on accurate material yield criterion and hardening models considering Bauschinger effect is urgently needed.The roll forming of variable height roll-die forming is a brand new roll forming process aiming at the requirement for lightweight parts of automobiles.In order to study the material deformation mechanism and better guide process optimization in the process,and the variable-section forming part of the roll forming of roll-die forming production line was studied theoretically.The theoretical derivation based on the Hill48 yield criterion and isotropic hardening model and the Hill48 yield criterion and kinematic hardening model were carried out,and the solution method of the model parameters was proposed.The finite element simulation of the roll forming of variable height roll-die forming provides a theoretical basis.The finite element model with different element types was established for the roll forming of variable height roll-die forming,and its finite element simulation analysis was carried out.The finite element model of different unit types is based on the "U"shaped part as the initial test part,which is based on the Hill48 yield criterion and isotropic hardening model and the Hill48 yield criterion and kinematic hardening model.The full-process finite element simulation is performed using ABAQUS.Combined with the experimental results,a comparative analysis was conducted to establish the most suitable finite element modeling method for the process.Based on the above research results,a full-process process design calculation and three-dimensional drawing of a roll forming-bending circle continuous forming process was performed for the "W" cross-section high-temperature alloy parts.Considering that the material undergoes significant loading and reverse loading during roll forming and subsequent bending circle,the application of kinematic hardening model to describe the necessity of Bauschinger effect is proposed.Finite element simulation based on finite element software ABAQUS,finite element simulation results of roll forming-bending circle continuous forming of the "W"cross-section parts were analyzed in depth to determine the feasibility of the process.It provides a reliable theoretical basis for the development of roll forming-bending circle continuous forming production equipment for "W" cross-section parts,as well as process optimization and promotion.