FEA Modeling And Processes Analysis Of Three Dimensional Flexible Roll Forming

Three dimensional roll forming is a new process in plastic processing field. Compared with traditional roll forming, it is provided with advantages in solving the complex cross-section of metal materials, difficulties in sheet forming and low efficiency. With the development of lightweight technology, high strength steel products with three dimensional roll forming process have showed great advantages in the field of vehicles, high-speed trains and aerospace. However, the three dimensional forming process of high strength steel is very complex and it is three-dimensional large formation with multi factors coupling interaction, accompanied with material nonlinearity, geometric nonlinearity and boundary condition nonlinearity. The forming theory of three-dimensional roll forming is still under developed, and it cannot be confirmed whether the metal formation is reasonable or not in early stage of process, so it is very important to use finite element method in analyzing the formation mechanism of high strength steel with three-dimensional roll forming process.This project has been analyzed material forming based on the theory basic mechanics, the theory springback, the theory elastic-plastic instability, the theory finite element algorithm of three dimensional roll forming, and has been studied in mechanics and finite element algorithm of three dimensional roll forming about theories. Then, predict the material deformation behavior in three dimensional roll forming.Material stress strain relations are foundations in analysis deformation behavior. Also, it is one of the key elements of improving the FEM forming simulation precision. For TRIP590high strength steel, material performance is tested by metal material tensile test. Based on three dimensional roll forming in high strength steel, materials meet plane strain stress state in bending deformation, having been choose a proper constitutive equation by plane strain extension test, and study the mechanical behavior of TRIP590high strength steel in three dimensional roll forming.For automobile B-pillar lower reinforcing plate forming process, nonlinear finite element analysis software ABAQUS can be used to simulate the whole forming process. The validity of the established simulate model can be verified by comparing the cross-section of simulate fonning part with the experiment result. Through the comparison, the simulation result with material constitutive relation of Swift type is considered to be fit better with the experiment result. Also, by analyzing the stress, equivalent plastic strain and the thickness of the simulation result using constitutive relation with Swift type and test obtained respectively, the Swift type has been proved to be more efficient in improving the FEM forming simulation precision of TRIP590high strength steel.