Simulation Design of Continuous Flexible Roll Forming Bending Process

Abstract

Simulation is a very helpful and it becomes a useful tool in the field of roll forming. Simulation provides a low cost, secure and fast analysis tool. The process and roll design for flexible roll forming of a sheet with varying cross-section was investigated. In order to obtain a constant bending width, rotational speeds, locations, orientations and dimensions of the rolls were calculated following the unfolding prediction of the sheet metal. The simulation is elaborated by using ABAQUS software working together with elastic–plastic modules which we developed taking into account of interactions between these fields. The application of this method makes it possible to highlight the strain-stress and mechanical behavior laws and procedures the spring-back. Thus, the flexible roll forming bending process with different shape can be eliminated by the simulation software and make a clear guide for the actual machine to work.