THE EFFECTS OF ROLL FORMING PASS DESIGN ON EDGE STRESSES

Roll forming is the process of bending welded pipe, tube, closed or open profiles from sheet metal strips by using rolls and reels. In this study, the roll design processes of the roll form machines and the stages of designing rolls according to a C-type profile with the Ubeco PROFIL® software are examined. The manufacture of rolls is the most important parameter that affects the costs in roll forming lines. It is essential to keep the number of stations and the rolls used in these stations at an optimal level according to the product to be rolled. It is possible to calculate the number of passes where the profile can be formed most appropriately, to determine how the rolls should be positioned and to obtain the technical drawings of the rolls that need to be manufactured for each station with the help of roll forming software products. This study examines the edge stresses and optimum amount of rolls at the stations where the product can be rolled without exceeding the strain limits.

Keywords:

Roll forming, sheet metal forming, roll design, edge stresses pass design,

PDF

___

[1] Han Z.-W., Ren L. Q., C. Liu & Lu W. P. (2001). Modelling of cold roll forming of steel strip. Materials Science and Technology, 17.4: 415-418.
[2] Sheikh, M. A., & Palavilayil R. R. (2006). An assessment of finite element software for application to the roll-forming process. Journal of Materials Processing Technology, 180.1: 221-232.
[3] Jeong, S. H., Lee, S.H., Kim, G.H., Seo, H.J., Kim, T.H. (2008). Computer simulation of U-channel for under-rail roll forming using rigid-plastic finite element methods. Journal of Materials Processing Technology, 201.1: 118-122.
[4] SHAPE Corp., Metal Processing. Retrieved December 10, 2016, from http://www.shapecorp.com/about/steel-processing/, 2009.
[5] UBECO PROFIL, Rollform Design Software. Retrieved December 15, 2016, from http://www.ubeco.com/profil.htm.
[6] Data M Scandinavia AB, Software for Roll Forming-COPRA®RF (2012). Retrieved February 5, 2017, from http://www.datam.de/en/products-solutions.
[7] Roll Forming Services Inc., Roll Forming Software-Simply Roll Design (2011). Retrieved February 5, 2017, from http://www.rollformingservices.com/software.
[8] Lindgren, M. (2007). Cold roll forming of a U-channel made of high strength steel. Journal of Materials Processing Technology, 186.1: 77-81.
[9] Safdarian, R., & Naeini H.M. (2015). The effects of forming parameters on the cold roll forming of channel section. Thin-Walled Structures, 92: 130-136.
[10] MSC software, Marc Advanced Nonlinear Simulation Solution (2017). Retrieved October 10, 2017, from http://www.mscsoftware.com/product/marc.
[11] Oh, M., & Kim, N. (2008). Optimum design of roll forming process of slide rail using design of experiments. Journal of Mechanical Science And Technology, 22.8: 1537-1543.
[12] Zeng, G., Li, S.H., Yu, Z.Q., Lai X.M. (2009). Optimization design of roll profiles for cold roll forming based on response surface method. Materials & Design 30.6: 1930-1938.
[13] Halmos, George T. (2006). Roll Forming Handbook, ISBN: 0-8247-9563-6, Taylor & Francis Group (CRC press).
[14] Donmez, O. E. & Kocabas H. (2008) Experimental Investigation of Edge Waviness During Cold Roll Forming of Thin Sheet Metal. İTÜ Dergisi/d Mühendislik 8.2: 127-135.
[15] Donmez, O. E. (2015). Experimental Investigation and Finite Element Analysis of Edge Waviness Defect During Cold Roll Forming of Thin Sheet Metal. PhD Thesis, Istanbul Technical University, Institute of Science, Istanbul.
[16] Gülceken, E. (2006). Modelling of a Flexible Roll Forming, Master Thesis, Istanbul Technical University, Institute of Science, Istanbul.
[17] Groche, P., Zettler, A., Berner, S. & Schneider, G. (2011). Development and verification of a one-step-model for the design of flexible roll formed parts. International Journal of Material Forming, 4.4: 371-377.
[18] M.M. Kasaei, M.M., Naeini, H.M., Abbaszadeh B., Silva, M.B., Martins, P.A.F. (2016). Flexible roll forming. Materials Forming and Machining: Research and Development 51.
[19] Yoon, J.S., Kim, J. & Kang, B.S. (2016). Deformation analysis and shape prediction for sheet forming using flexibly reconfigurable roll forming. Journal of Materials Processing Technology, 233: 192-205.
[20] Jenkouk, V., Hirt G., Franzke M., Zhang T. (2012). Finite element analysis of the ring rolling process with integrated closed-loop control. CIRP Annals-Manufacturing Technology, 61.1: 267-270.
[21] Wiebenga, J. H., Weissb M., Rolfe B., van den Boogaard, A.H. (2013. Product defect compensation by robust optimization of a cold roll forming process. Journal of Materials Processing Technology. 213.6: 978-986.
[22] Shim, D.S., Kim, K.P., Lee, K.Y. (2016). Double-stage forming using critical pre-bending radius in roll bending of pipe with rectangular cross-section. Journal of Materials Processing Technology. 236: 189-203.
[23] Sheet Metal Forming, (2009). Retrieved October 10, 2017, from http://www.custompartnet.com/wu/sheet-metal-forming.
[24] Livatyalı, H. (2006). Bilgisayar Destekli Roll Form Makara Tasarımı: Zanaatın Teknolojiyle Birleşmesi. TurkCADCAM.net Dergisi, Volume 2.
[25] Gradous Fred, (1966). Roll form design - how many passses, Tool. Prod., pp. 115.
[26] K. H. Grote and E. K. Antonsson, (2009). Springer Handbook of Mechanical Engineering, ISBN: 978-3-540-49132-3, Springer Publishing, pp: 593.
[27] Erdemir Group, (2005), Cold Rolled Flat Steel Products, pp: 13, 21.

Sigma Mühendislik ve Fen Bilimleri Dergisi-Cover

ISSN: 1304-7191
Yayın Aralığı: Yılda 4 Sayı
Yayıncı: Yıldız Teknik Üniversitesi

Arşiv