The Numerical Analysis And Optimization Of The Roll Bending Process Of Wire Based On ANSYS

The quality of bend metal depends on the technology parameters which are always determined by the designers' experience. To compensate shape deviation, the traditional practice uses trial-and-error approaches to obtain desired part. Its economic impact in terms of delayed production, tooling revision costs, and rejection of unqualified parts is tremendous. The metal forming process simulation technology can simulate the process and forecast the design limitations. So, efficiency is improved, time is saved and cost is reduced. The quality of the wire directly affect the rationality, safety and reliability of industrial structure, which have been used widely in industry. It always produces springback which is hard to forecast and mainly affect the quality of wire in the forming process of wire, which is a problem difficult to solve.This paper researches on the process of roll bending of wire based on finite element simulation. The main research contents include:(1) Aiming at the problem of forecasting the springback hardly, an mathematical model is derived based on the factor of force arm and the correct degree was verified in some condition by the simulation test.(2) The establishment of mathematical model of springback is based on the conclude that arm of force is an important factor affects the springback through the finite element simulation and a test scheme designed using orthogonal method.(3) An optimization model is put forward based on the conclude that arm of force is an important factor affects the springback and a loading curve of motion is derived whose validity is verified in the next simulation test.(4) It hopes to adopt a material model nearer to the practical state because the material model used in this paper is an ideal elastic-plastic model .Also, it hopes to be modificatied in the next step because that errors exist in the mathematical model of springback.