An experimental and modelling approach for improving utilization rate of the cold roll forming production line

This paper presents theoretical approach and complex experimental research which was conducted within the real production conditions of cold roll forming channel sections. The experimental investigation was focused on forming forces measuring on the rolls and the deflections of roll stands due to the forming loads. The comparison and analysis of the obtained experimental results was performed for the majority roll stands. Based on the experimental results mathematical modelling of the forming a force‐roll load was performed by response surface methodology for different values of the input parameters of the process: material properties, sheet thickness, and sheet width. The defined force model and experimental research show insufficient energetic and technological utilization of the existing production line. After the conducted research in the production process a sheet thickness of up to 1.40 mm is used instead of 0.70 mm, and the utilization of the installed energy has increased from 20 % to 75 %. This is confirmed by the measured deformations of the roll stands and the energy consumption of the powered electric motor. Through realized modernization of the cold roll forming production line, 30 % higher productivity is achieved, which is a result of optimal number planning of roll forming stations and approximately the same load of all roll stands, as well as the higher flow rate of the profile sheet.

[1]  Konstantinos Salonitis,et al.  Investigation of the effects of main roll-forming process parameters on quality for a V-section profile from AHSS , 2009 .

[2]  Jean-Philippe Ponthot,et al.  Numerical simulation of cold roll-forming processes , 2008 .

[3]  Xinmin Lai,et al.  Optimization design of roll profiles for cold roll forming based on response surface method , 2009 .

[4]  Karl Kuzman,et al.  Problems of accuracy control in cold forming , 2001 .

[5]  Guoqing Chen,et al.  A new mathematical model for determining the longitudinal strain in cold roll forming process , 2015 .

[6]  Michael Lindgren,et al.  Cold roll forming of a U-channel made of high strength steel , 2007 .

[7]  Peter Groche,et al.  Experimental and numerical investigation of the bending zone in roll forming , 2017 .

[8]  Konstantinos Salonitis,et al.  Energy efficiency of cold roll forming process , 2013 .

[9]  P. D. Smith,et al.  The prediction of roll load in cold roll-forming , 1987 .

[10]  Yu Yan,et al.  Investigations of fracture on DP980 steel sheet in roll forming process , 2016 .

[11]  Pedro Ferreira.  Roll Forming - a study on machine deflection by means of experimental analysis and numerical developments , 2016 .

[12]  George Halmos,et al.  Roll Forming Handbook , 2005 .

[13]  Konstantinos Salonitis,et al.  Optimization of roll forming process parameters—a semi-empirical approach , 2010 .

[14]  Milan Jurković,et al.  AN INVESTIGATION OF THE FORCE AND TORQUE AT PROFILE SHEET METAL ROLLING - INPUT DATA FOR THE PRODUCTION SYSTEM REENGINEERING , 2015 .