One-Time Roll-Forming Technology for High-Strength Steel Profiles with “日” Section

Jicai Liang,Yi Li,Aicheng Wang,Guangyi Chen,Ce Liang,Xiaoming Li,Chuandong Chen

doi:10.1155/2019/6505914

Jicai Liang, Yi Li + Show 5 more

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https://doi.org/10.1155/2019/6505914

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Abstract

Roll forming is an important processing method for the production of commercial vehicle anticollision beams, and edge buckling is one of the common defects in roll-forming process. In this paper, the “日” shape section of roll forming is studied, and first the b-shaped section is formed by roll forming, and the internal weld line is automatically welded while forming; then the long side of the b-shaped section is bent into the “U” shape, and the external weld line is welded while forming. The profile is cut off and then bent at both ends to form a commercial vehicle anticollision beam. The ABAQUS finite element software is used to model and analyze the factors affecting the “edge buckling” defect of roll-formed products. This paper uses three factors and three levels of orthogonal simulation experiments to study the problem. The results show that the effect of the factors of flange height, sheet thickness, and forming speed on the formation of edge buckling is in the order of sheet thickness > flange height > forming speed. The edge buckling size of the vertical edge of b-shaped tube decreases with the increase of sheet thickness and increases with the increase of flange height.

Highlights

IntroductionBy using ABAQUS finite element software for numerical simulation, it is convenient and efficient to study the forming law of roll-forming process, master the technological conditions affecting its forming effect, avoid the waste caused by “trial and error method,” effectively improve the product forming quality, and create greater production value [5]
In order to further explore the effect of sheet metal thickness and flange height on the flange edge buckling of “b” tube, two sets of comparative simulation experiments are designed in this paper
COPRA is used for pass design, ABAQUS is used for finite element modeling and analysis, and orthogonal experiments and comparative experiments are designed to study the roll-forming law of the b-shaped tube, which provides theoretical basis for the production of “日” shape tube. e conclusions are as follows: (1) Compared with the traditional roll-forming method, the application of new roll-forming technology in this paper improves the material utilization rate and production efficiency and ensures the mechanical properties of the products, such as tensile strength, bending strength, and impact toughness

Summary

Introduction

By using ABAQUS finite element software for numerical simulation, it is convenient and efficient to study the forming law of roll-forming process, master the technological conditions affecting its forming effect, avoid the waste caused by “trial and error method,” effectively improve the product forming quality, and create greater production value [5]. Tehrani et al [10, 11] conducted a finite element simulation study on the phenomenon of edge buckling in the roll-forming process and found that if the bending angle of the sheet metal in the first forming process exceeded a specific limit, it would appear edge buckling in the subsequent second roll-forming process. Wang and Fei [13] studied the effect of sheet thickness, arc radius, side leg height, and bending arc length on side leg wrinkling through orthogonal simulation experiments, which provided a basis for the formulation of roll-forming process and finite element model

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Results

Conclusion