Fea Simulation Study With Variable Cross-section Of Cold Roll Forming

Roll forming is one processes of the metal forming of plasticity, which is complex and contains many aspects such as mechanics, elastic-plastic mechanics, kinematics and dynamics, etc. When analysing the forming of the process, it involve not only transverse bending deformation, but also longitude tension deformation. As the theory is complex and difficult to get the results, now the roll design based on experience, and its technology accomplish by test and error, or direct on doing experiment to get the law of the process or to identify the roll design.Flexible roll forming is a new kind technology of roll forming. It contains Artificial intelligence technology, Computer control technology, etc. By using the roll forming technology, it is possible to produce profiles with variable cross section along their longitudinal direction. By use of FEA software MSC.Marc, This paper is first to simulate and analyze the flexible roll forming process in China, and studied the deformation and shaping of the variable cross section, when the section changed its cross section degree small along the longitudinal direction, and use the axis roll in stead of normal roll.The simulation results, when in the condition, indicates the deformation defect and offset error of the section, and it can estimate and suggest the apply area of the technology, when the section changed its cross section degree small along the longitudinal direction, and use the axis roll in stead of normal roll.As to geometry deformation theory, when foming section use the axis roll in stead of normal roll, the pratice bend area of the section will displace the design area. The simulation results analyzed the biggest displace of a series variable sections of small digree. It concluded that: when bend degree of the section is more than 90 degree, should use the edger roll;As the changed degree of the cross section along the longitudinal direction increase, the displace of the bend area and section edge also increase.Above all, the author simunated the flexible roll forming and get a series valuable conclusion of the section deformation defect and offset error, it can offer reference and experience for the flexible roll forming industries, design and production.