Explicit dynamics finite element analyses of asymmetrical roll bending process

Abstract

In this article, results obtained from a preliminary study that contains a set of explicit dynamics finite element analyses of a metal plate bending process are presented through 3D asymmetrical three roller models. ANSYS Ls-Dyna explicit dynamics finite element (ED-FEA) preprocessor and solver were used to carry out dynamic simulations. Explicit dynamics of a low-velocity process such as the roll-bending of a metal plate is a computationally expensive method. Since plastic deformation occurs on the plate in addition to elastic flexure to eventually possess a circular geometry, the plate material is considered a non-linear material. In this particular study, an aluminum plate was modeled with the Bilinear Kinematic Hardening model including plasticity parameters such as the tangent modulus. A very significant parameter called the mass scaling factor was taken into account to be able to define a specific time-step that was used to determine the computation time interval and the total temporal cost. However, exaggerated reduction of the computation time results in unphysical consequences. The results were presented before and after redesigning the lower and side rolls having a convex geometry and the peripheral velocity of upper roll rotation was decreased to minimize the distortion that occurred on the pre-bent side walls of the aluminum plate.