The Technology Of Micro Roll Forming And Simulation

Roll forming is a process technology in which a plurality of forming rollers are sequentially arranged to continuously bend the metal sheet and strip to make a specific cross-sectional profile.It is a material-saving,energy-saving,high-efficiency,advanced and applicable sheet metal plastic forming process.Microforming refers to the technology of using plastic deformation of materials to produce parts with dimensions in the millimeter or sub-millimeter order in at least two dimensions.This paper takes the current forming process of W-shaped sealing ring for aeroengines as the starting point and proposes to combine the above two processes,which named micro roll forming process can be used to produce such parts.It provides new ideas for the forming process of such parts.This paper presents a complete W-shaped sealing ring forming process,which is uncoiling,straightening,roll forming,rounding,and welding.Compared with the current existing forming process,the proposed process can produce parts with small shapes and complex cross-sectional shapes.During the forming process,the sheet will produce redundant deformation,including warping,distortion,side waves,thinning,damage,tearing and so on.According to the theory of plasticity,the forming process of the sheet is explored to reduce the occurrence of forming defects.The finite element simulation of the W-shaped sealing ring micro-roll forming process is completed for the GH4169 sheet.Based on the basic mechanical performance parameters of GH4169,a finite element model of the W-shaped sealing ring micro roll forming process is established with the geometric model,algorithm selection,contact boundary,mesh division and other problems in the finite element simulation process are solved.According to the calculation results,the analysis of forming force,stress field,strain field,thickness reduction and the whole process of forming are completed.The finite element simulation results are used to analyze the deformation behavior of the sheet,in order to adjust the process parameters,and optimize the forming process.In the process of finite element simulation of the W-shaped seal ring micro-roll forming process,the roll forming line modeling process was cumbersome,time-consuming and prone to human operation errors.Based on the Python language,the secondary development of roll forming finite element simulation was conducted.The newly developed plug-in is used to quickly set up roll forming production lines,which improves modeling efficiency and model accuracy.The function of the plug-in is verified by the comparison between the roll forming test results and the finite element simulation results.