Research on roll-forming bending angle distribution function based on five boundary conditions

Abstract

The bending angle is an important parameter in roll forming, in which the rationality of the bending angle distribution in each pass directly impacts roller design, the smoothness of the roll-forming process and product quality. In the past research, it is generally recognized that the projection track of the edge of the profile section in the horizontal plane follows a cubic curve, which can be used to determine the bending angle of each pass according to the boundary conditions. However, this method has some limitations and does not guarantee that the distribution of the bending angle is the most acceptable one. In this study, a hat-shaped steel channel is chosen as the research object and the different bending angle distribution methods are discussed. In addition, a bending angle distribution function based on five boundary conditions is proposed and the curve equation for the projection track of the edge of the profile section in the horizontal plane is constructed. At the same time, different bending angle distribution results are obtained by adding various boundary conditions, furthermore, the numerical simulations and comparative analyses are performed. Finally, combining the numerical simulation with the experiment, the optimal bending angle distribution results are obtained.