Flexible Roll Forming Simulation Research

Flexible roll forming is a kind of new roll forming process, comparing the traditional roll forming products; they have more reasonable bearing capacity, and can realize the lightweight. Flexible roll forming profiles in automobile and building have a good application prospect. But both at home and abroad for a flexible roll forming process of its application research is less limit.Through the finite element simulation method, this paper discusses the process of flexible roll forming, including strips and shaping roller speed matching relation between the cross-section area, stress and strain distribution, forming parameters and the relationship between the product shape etc. Through the simulation research of flexible roll forming, we obtain the basic parameters for flexible roll forming and development of technology to provide technical reference.Using the nonlinear finite element analysis software MSC. Marc the molding process of flexible roll forming is simulated. In the process of simulation, the forming roller is simplified to a rigid, except that the forming roller rotation axis around oneself, but also guarantee the lateral movement and along the axis of rotation around plumb-lines, plank to consider is the thin body, by using software quadrilateral shell element function, the successful implementation of the contact in profile cross-section of the forming roller translation and rotation, especially in the static implicit algorithm of static bending forming simulation of flexible roller, and puts forward the control points and the forming roller motion control method, the realization of the forming roller translation and rotation, which is for the use of flexible roll bending software Marc simulation research provides a method of forming, realize flexible roll forming of finite element modeling.Based on the static implicit algorithm for U shaped cross-section bending roll a finite element simulation, and presents U shaped cross-section bending roll of simulation results of different legs, analyzed the U shaped cross-section transition region strain and stress variation analysis of bending roll and the flexible forming three working rollers, legs, the waist with local deformation of corner, with the increase of leg, high tensile strain rate's edge and increase, high change, but leg high rate of change slow, roller corner, but roll change slow the rate of change corner, cross-section transition area biggest increase, but increased drape the rate unchanged.