DESIGN AND SIMULATION OF ROLL FORMING PROCESS FOR UNDER RAIL

Abstract

Cold-roll-forming (CRF) is a well known process used to manufacture long sheet metal products with a constant cross section. It can manufacture products of the uniform cross section on a large scale as a continuous processing. However, process analysis is very difficult because of the inherent complexity. Therefore, time is consuming and analysis much money are needed for manufacturing goods. In order to overcome this difficulty, a new computational method based on the rigid-plastic finite element method is developed for the analysis of roll forming process and the optimal design. In this paper, to manufacture the upper member at under rail composed of three members, the design of roll forming process and the simulation are performed. Tensile test is performed about SCP-1 to obtain material properties and curve fitting is executed to set up the flow stress equation. The flower pattern of the upper member in the under rail is designed. The final shape is predicted after simulation. The longitudinal strain is estimated on the basis of simulation results. In addition, the numerical magnitude of bow and camber are predicted from the results of the simulation.