Research on the Mechanism and Processability of Roll Forming.

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Cold bending forming of thin-walled circular tubes presents challenges like edge bulging and waviness.
• Product quality is highly dependent on precise control of forming process parameters.

Purpose of the Study:

• To compare four cold bending methods and identify the optimal technique for thin-walled circular tubes.
• To analyze the influence of process parameters on strain distribution and roller forces using numerical simulations.
• To evaluate the suitability of high-strength steel materials in this forming process.

Main Methods:

• Comparative analysis of four distinct cold bending forming methods.
• Numerical simulations using COPRA software (COPRA FEA RF 2023.1) based on the combined bending method.
• Analysis of equivalent plastic strain, work hardening, thickness strain, and cross-sectional forming.

Main Results:

• The combined bending method was identified as the optimal forming technique.
• Processing speed showed minimal impact on equivalent plastic strain and work hardening.
• Increased spacing between upper and lower rollers significantly reduced equivalent plastic strain and roller moment.
• The study confirmed the advantages of forming high-strength steel plates.

Conclusions:

• The combined bending method offers superior control over defects in cold forming thin-walled tubes.
• Optimizing roller spacing is crucial for managing strain and forces, especially when working with high-strength steels.
• Numerical simulation results align well with experimental data, validating the study's findings.