Research On Process Design And Optimization Of Flexible Continuous Cold Forming

A flexible continuous cold bending process is designed and optimized in this paper.This process can be used for continuous cold bending of high strength rectangular tubes and allows the process to produce a lot of specifications.The sample product of design is 170×170×9.5mm rectangular tube with high strength steel WYS700.The first is the raw material plate design and the choice of rolling mill.Then is the design of each pass.The third place is each pass of the roll design.The last process use ANSYS/LS＿DYNA command flow for secondary development and complete modeling and forming process finite element simulation.The analysis of the simulation results shows that the distribution of stress and strain in each pass is good.The symmetry of the product is also good.There is no longitudinal bending defect of the tube,but the shape and quality of the outer edge of the tube are poor and slightly wavy defect.The effectiveness of the model was verified by comparing the hardening effect of cold working at angles between simulation and experiment.In order to optimize the side wave defects of billet,the virtual test scheme of each pass bending Angle and roll diameter was designed.The positive strain ε along the tangent direction of the outer edge of each test scheme was calculated by finite element simulation.A regression equation was established to describe the positive strain εobtained from the test with the roll diameter and bending Angle corresponding to the test pass.SPSS software was used for data analysis.The established regression equation was fitted,the fitted regression equation was planned and solved,and the bending Angle and roll diameter were obtained when ε of each pass was the minimum value.When 0.5%< maximum ε<0.9%,the optimization is complete.The optimized results ensure that the product edge has no wave shape and the rolling capacity of each pass mill can be fully developed.