Optimization of required torque and energy consumption in the roll forming process

Abstract

Exact estimates of the power required in manufacturing processes prevent machines from being designed with capacities that are several times greater than those required. Owing to the high energy consumption in the manufacture of tubes and profiles, in this study and considering the effects of some input parameters (including the bend angle increment at each stand, internal distance between the stands, strip thickness, channel flange width, and corner radius) in the production of a symmetrical channel section, the energy consumption and required torque were investigated and optimized using the full factorial method. The results showed that an increase in the bend angle increment at each stand increases the required torque and changes the energy consumption, so an increase in the bend angle increment at each stand from 30° to 60° could save 1 kJ energy for each meter of the product. Moreover, reductions in the flange width and strip thickness reduce the torque and energy for each unit length. The effects of the distance between stands on the energy and the torque depend on the bend angle increment at each stand. Consequently, at lower angle increments, the reduced distance between stands increases the energy consumption and required torque.