Study Of Asymmetric Corrugated Groove Roll Forming Defects And Influencing Factors

Aluminum sleeve is made of asymmetric corrugated channels by spin forming process.Compared with the thesis sleeve commonly used in industrial coils,it has the advantages of low cost,light weight,strong compressive ability,recyclability,environmental protection,and no pollution and so on.Therefore,it has broad market development prospects and promotion value.However,as a primary product for making aluminum sleeve,the stress-strain behavior of asymmetric corrugated channels roll forming is very complicated,which makes the defects difficult to predict and control.And thus,the quality of final forming products is affected inevitably.For this reason,the longitudinal bowing and slip camber defects caused by the roll forming asymmetric corrugated channels are studied,respectively.And their influencing factors are analyzed,in order to realize the effective control of defects.The main research contents are as follows:(1)Based on the basic theory of explicit kinetic elastic-plastic finite element method,the stress-strain behavior of asymmetric corrugated channel roll forming is simulated by simultaneous-and sequential forming methods,respectively,through using the finite element analysis software ABAQUS.And the better forming method is determined by analysis of their stress-strain behavior and forming accuracy.(2)The longitudinal bowing mechanism of the sheet is elucidated.And then,the influence of roll station distance,yield strength,and forming angle increment and other parameters on its longitudinal bowing defect and control methods are studied,through using the implicit statics to simulate the springback process of sheet.(3)The forming defects of transverse slip camber are studied.The influence rules of friction coefficient,roll station distance,forming speed,bending angle strategy,yield strength and other parameters are analyzed,and then,the forming parameters are optimized.(4)Based on the optimized forming method and forming parameters of asymmetric corrugated channels,the experimental verification of their forming quality is carried out.