Simulation and Experimental Study on Roll-Forming Limit of Cup

Area of Science:

• Manufacturing Engineering
• Materials Science

Background:

• Roll forming offers improved material utilization and efficiency for curved profiles like cups.
• A lack of established forming limits hinders optimization in cup roll forming.

Purpose of the Study:

• To determine the forming limit for roll-forming cups.
• To analyze factors influencing the forming limit and damage.
• To develop a roll-forming limit diagram for cups.

Main Methods:

• Finite element analysis using DEFORM-3D software to simulate cup roll forming.
• Analysis of damage values and velocity vectors under various parameters.
• Experimental verification of the established forming limit diagram.

Main Results:

• The forming limit for billet wall thickness in cup roll forming is approximately 62%.
• Increased ratio of formed cup wall thickness to billet bottom thickness slightly reduces the forming limit.
• Optimizing roller radius, punch fillet radius, and friction coefficients improves the roll-forming limit and reduces damage.

Conclusions:

• A roll-forming limit diagram for cups has been successfully established through numerical simulation and experimental validation.
• The study provides a basis for determining forming limits in the roll forming of cups.
• Optimized process parameters are crucial for maximizing the roll-forming limit and minimizing defects.