Abstract
Roll forming can improve the material utilization rate and production efficiency of cups with a curved rotary profile, but there is no basis for the determination of forming limit. The DEFORM-3D software was used to simulate the roll forming of cups. The influence of the billet wall thickness and bottom thickness, coefficient of friction, radius of roller, and the fillet radius of the punch on the forming limit was studied, and the damage value and velocity vector were analyzed. The results showed that the forming limit of the billet’s wall thickness in roll forming for a cup is about 62%. With the increase of the ratio of the formed cup’s wall thickness to the billet’s bottom thickness, the forming limit of wall thickness will be slightly reduced. A larger radius of roller, fillet radius of punch, and friction coefficient between punch and billet and a smaller friction coefficient between roller and billet are good for decreasing the damage value and improving the roll-forming limit. According to the numerical simulation results, the roll-forming limit diagram of cups is established, and the accuracy of the forming limit diagram is verified by experiments.
Highlights
Cups with a curved rotary profile are common parts in industrial production
For the purpose of both meeting the requirements of mass production and increasing the material utilization rate of a cup with a curved rotary profile, a new technology, roll forming, was proposed on the basis of roll forging and drawing
The abscissa in the figure is the ratio of the wall thickness of the formed cup to the bottom thickness of the billet (t1/td), and the ordinate is the deformation of the wall thickness ε: The roll-forming limit diagram shown in Figure 10 can be obtained by Table 2
Summary
Cups with a curved rotary profile (as show in Figure 1) are common parts in industrial production. For the purpose of both meeting the requirements of mass production and increasing the material utilization rate of a cup with a curved rotary profile, a new technology, roll forming, was proposed on the basis of roll forging and drawing. The influence pushed by the downwardly moving punch and makes the pre-forming ro of the triangular flash groove of pre-forming rollers on the quality of roll-formed parts curved rotaryand profile of the flash cupgroove is formed the specific grooveofshape o has been studied the optimized was putby forward [15]. The roll-forming process was compared with the traditional p aspects (a) of material utilization, productivity, forming (b) force, dies cost machining time [20,21]
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