Finite Element Simulation of Roll Forming
Independent thesis Advanced level (degree of Magister), 20 points / 30 hpStudent thesis
A finite element model has been developed to simulate the forming of a channel section profile with the roll forming method. The model has been optimized to experimental results with respect to strains at the edge of the sheet and spring back of the sides of the profile. Finite element models with a coarse mesh have been compared to models with a finer mesh. The models with to fine mesh become instable and a model with a rather coarse mesh was finally chosen.
Both the models with shell elements and the models with solid elements have been used in the simulations. The simulations with shell elements gave very good results both for the geometry shape and the strains at the edge of the sheet. The reaction forces at the tools found in the simulations was only half of the reaction forces fond in the experiments.
The simulations with the solid element model showed very good results for the reaction forces while the geometry shape of the sheet was really bad. The spring back was much larger in the simulations than in the experiments.
The shell element model was chosen because of the excessive spring back with the solid element model. The spring back of the sides of the sheet differs only a few percent between the simulation and the experiment results when using the shell element model. The reaction forces at the tools in the simulation are only half of the reaction forces measured in the experiments but the results from the simulations are linearly proportional to the results in the experiments. The model that finally was chosen describe both the spring back and the strains at the edge of the sheet very well. Like in the experiments there were no signs of wrinkles at the sheet in any of the simulations.
Place, publisher, year, edition, pages
2007. , 81 p.
Rullformning, Simulering, Ultrahöghållfast stål, Rollforming, Finite Element Simulation.
Reliability and Maintenance
IdentifiersURN: urn:nbn:se:liu:diva-8312ISRN: LIU-IEI-TEK-A--07/0044--SEOAI: oai:DiVA.org:liu-8312DiVA: diva2:23138
2007-01-12, Linköping, 09:15