Roll forming is an important forming process for profile manufacturing in mass production. The design of the process has an important influence on the quality of the products. Therefore, the knowledge of the occurring loads during the roll forming process, e.g. forces and pressures, is essential for the process design. However, the experimental determination of the occurring contact normal pressures in roll forming processes poses a challenge. Finite element simulations offer the potential to approximate contact normal loads and thus, enable a better process design. Nevertheless, due to simplifications of the numerical model, a realistic and reliable output of loads in roll forming is not possible. An enhanced numerical model could provide more valuable information. This paper will demonstrate the reproduction of realistic contact normal pressures and load forces in a roll forming simulation. To verify the numerical values, they will be compared to data gained by experiments.
[1]
Peter Groche,et al.
Roll-Forming of Branched Profiles
,
2009
.
[2]
Jon Larrañaga,et al.
Geometrical accuracy improvement in flexible roll forming lines
,
2011
.
[3]
Michael Lindgren.
Validation of finite element model of roll forming
,
2008
.
[4]
Michael Lindgren,et al.
Experimental investigations of the roll load and roll torque when high strength steel is roll formed
,
2007
.
[5]
Peter Groche,et al.
Accelerating the FE‐Simulation of Roll Forming Processes with the Aid of specific Process’s Properties
,
2011
.
[6]
Peter Groche,et al.
Experimental and Numerical Determination of Roll Forming Loads
,
2014
.
[7]
Peter Groche,et al.
Development and verification of a one-step-model for the design of flexible roll formed parts
,
2011
.