Simulation of roll forming process with the 3-D FEM code PAM-STAMP

Abstract Roll forming is a well known process used to manufacture long sheet metal products with constant cross section. Despite the long history of the process, the design procedure for the roll formed products, forming rolls, and roll pass sequences still remains more an art than a science. Thus, to avoid forming defects and to reduce the process development efforts, finite element analysis can be used to predict strain distributions and sheet geometry during and after the process. This paper summarizes the results of roll forming simulations made with a commercial FEM code. Deformed geometry and strain distributions predicted by simulations are compared with the results from previously conducted experiments. This study provided considerable experience how and when it is best to apply a commercial 3-D FEM code to the design of a roll forming process.