Comparative analysis of analytical and numerical methods for defect prediction in u-channel roll forming
DOI:
https://doi.org/10.37142/2076-2151/2025-1(54)72Keywords:
roll forming, U-channel, stress-strain state, finite element method, longitudinal strain, forming stand, roll pass design.Abstract
Babai Y., Hubskyi S., Yavtushenko A., Koshkarov Y., Natarov M. Comparative analysis of analytical and numerical methods for defect prediction in u-channel roll forming
The aim of this study is to improve the accuracy of prediction and prevention of shape defects (specifically edge buckling) in the production of open-type roll-formed profiles by refining the methodology for stress-strain state analysis. Based on a comparative study of analytical and numerical modeling methods, the necessity of considering real physical factors of the process, such as contact friction and redundant deformation energy, is substantiated. It is established that geometric calculation methods tend to underestimate actual stress levels by predicting deformation within the elastic zone, whereas finite element analysis reveals critical zones of plasticity. Theoretical studies were conducted on the roll forming process of a U-channel made of Steel 10 using CAE systems. Finite element models of metal behavior in the forming stands were developed, allowing for an investigation into the dynamics of longitudinal strain accumulation at the profile edge. Based on the analysis of the obtained models, the influence of the roll forming mill's geometric parameters on product quality was determined. The feasibility of increasing the inter-stand distance as an effective method for mitigating wave formation has been proven. A comparative analysis of simulation results for various kinematic schemes showed that rationalizing the deformation base from 1000 mm to 1400 mm ensures a reduction in peak longitudinal strain values from 3.5 % to 1.2 %, thereby guaranteeing process stability and the absence of defects.
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