Analysis of the asymmetrical roll bending process through dynamic FE simulations and experimental study

Abstract

Because it is influenced by various processing parameters, predicting the bending force and improving the accuracy of the final shape are significant challenges in the roll bending process when the part to be produced is large and made of high-strength steel. In this paper, a 3D dynamic finite element (FE) model of an asymmetrical roll bending process is developed using the ANSYS/LS-DYNA software. This model investigates the parameters that affect the accuracy of the final shape, the bending forces, and the residual strains left in the formed plate. The simulation results are then compared with experiments performed on an instrumented roll bending machine. Strain measurements are also performed during forming with strain gauges fixed onto plate blanks. A good agreement between the experiments and simulations has been obtained.