FEA Simulation Of Roll Forming Process For Small-diameter Thick-walled Tube

Small-diameter thick-walled tube has a wide application in the production, but it has a lot of difficulties in the process of roll forming. In order to realize reasonable cambering in practice, we need more experience and trial-error design, the development of new products are repeated many times between design and practice , therefore, it is a longer cycle and also has a higher cost. With the finite element software is adopted to simulate the roll-forming process, the process is analyzed with the purpose of providing guidance on the application in actual production; it can cut down the cycle length and save cost.A number of sizes are selected from the "Practical Handbook of Iron and Steel" in this article, roll flowers are designed through the professional software COPRA. Using the method of elastic-plastic finite element analysis, nonlinear finite element software Msc.Marc is used for simulating the small-diameter thick-walled tube in roll-forming process. The roundness error is analyzed, and the polynomial equation is summed up according to the same diameter and the same wall thickness. The tube wall thickness changing is stated after roll-forming, and the peak point of the changing error is given.In the article, the conclusions can be used for high-precision welded tube roll forming process. A new conception for modifying the roller gap contour by the wall thickness changes is disclosed.