Finite Element Analysis Of Flexible Roll-die Forming Production Line With Laser-assisted Heating

Flexible roll-die forming is a new technology in plastic process, which can solve the problems that the traditional roll forming cannot achieve, such as changeable sections and unsymmetrical height of both sides of the sheet. On special occasions, some bearing parts with relatively narrow sections or very complicated sections will be needed. The normal flexible roll forming can’t realize one-time forming, so this paper puts forward a kind of one-time forming technology on bending parts with higher strength and smaller radius, namely flexible roll-die forming. It’s difficult to shape high strength steel because of its high mechanical property, poor plasticity and low elongation and also crack and springback are in the bending position. So this paper decides to use laser-assisted heating to solve the above problems.This paper is based on the analysis of fully couple for thermal-stress, and the forming process of the flexible roll-die forming with laser-assisted heating is constructed by ABAQUS software (Large finite element analysis software). Using DP980high strength steel as a research object, simulating the distribution of thermal field and stress field during forming process, analyzing the plastic strain areas and the variation of forming force about rollers, predicting the springback by compared with the relationship among forming angles. The main research work is as follow:(1) The thermal field:Introduce the study history and development status of thermal forming, analyze the method of thermal forming, set the intercoupling boundary conditions for the steel and moulds by using heat transfer theory and distribution of temperature field in shells. By comparing with different thermal field in the simulation process, the most appropriate processing temperature can be obtained.(2) The stress field:Analyzing the equivalent stress and strain, then the curves of forming force can be obtained, so we can master the changing regulation of the elastoplasticity during the forming process.(3) The forming velocity and springback prediction:Analyze the forming angles after the process, predict some possible springback in the forming process, and compare the simulation velocity and simulation results, in the end the relations of the forming effect and working speed can be obtained.The simulation of productive process about flexible roll-die forming with laser-assisted heating can be finished by thorough thermal mechanical coupling and finite element analysis. By comparing with the experimental results, the simulation results are correct. The results provide the basic theory for the analysis of thermal mechanical coupling in flexible roll-die forming with laser-assisted heating, and have important meaning for improving equipment and production practice.