Simulation of roll forming process with the 3-D FEM code PAM-STAMP

Heislitz, Frank; Livatyalı, Haydar; Ahmetoglu, Mustafa A.; Kinzel, Gary L.; Altan, Taylan

doi:10.1016/0924-0136(96)02287-x

Cited by 102 publications

(59 citation statements)

References 4 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Lindgren (2005) predicted the longitudinal membrane strain in the flange of a metal strip roll formed in a process consisting of six roll stands. The results correlated very well with those of Heislitz et al (1996). In their numerical investigation on edge buckling of a roll forming process producing a symmetric channel section, Tehrani et al (2006) validated their numerical results with strain gauge analysis and agreed with McClure and Li (1995) that the strain is positive/ tensile in the flange, and negative/ compressive in the web.…”

Section: Introductionsupporting

confidence: 71%

“…McClure and Li (1995) analysed a roll forming process with three passes using a three dimensional finite element model, and validated their investigation by measuring the strain with strain gauges, bonded to the upper and lower surface of the strip. Another three dimensional finite element prediction of a U-shaped cold roll forming process consisting of three passes was undertaken by Heislitz et al (1996). They found a continuous rise of longitudinal strain in the strip just ahead of each roll stand and comparison of their numerical work to previous experiments showed an approximate deviation of 10%.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Predicting plastic deformation and work hardening during V-band formation

Müller

Barrans

Blunt

2011

Journal of Materials Processing Technology

View full text Add to dashboard Cite

V-Band Clamps are manufactured using a cold roll forming process consisting of six passes which plastically deform an initially flat strip by bending to produce the band's V-section. In this paper a new method of validating numerically predicted plastic deformation in a cold formed metal strip is presented. Tensile testing of samples of the band's material was used to obtain a direct link between plastic strain and work hardness of this particular material. Using this correlation, the equivalent plastic strain (PEEQ) values predicted by finite element simulations were converted into hardness values.These values were compared to experimental work, in which samples of each pass of the roll forming process were taken to determine the work hardness in the cross section of the V-band using a microhardness machine. The error in strain predicted by the numerical method and hardness obtained by testing was found to be between 0.4% and 16.9%. This error was mainly due to uncertainty in material properties and the accuracy of the measurement technique. Compared to the more classical approach of measuring strain distribution with strain gauges, this method is more precise and accurate, as it is able to pick up even small changes in strain distribution.

show abstract

Section: Introductionsupporting

confidence: 71%

Section: Introductionmentioning

confidence: 99%

Predicting plastic deformation and work hardening during V-band formation

Müller

Barrans

Blunt

2011

Journal of Materials Processing Technology

View full text Add to dashboard Cite

show abstract

“…(McClure and Li, 1995) also employed shell elements and carried out validation using the strain gauge measured longitudinal strain. (Heislitz et al, 1996) used the explicit code PAM-STAMP. The strip was modelled using one layer of eight node brick elements, pulled through fixed frictionless rolls.…”

Section: Introductionmentioning

confidence: 99%

“…this is carried out by (Lindgren, 2007) and . The second approach is to move the non-rotating rolls with constant speed over the material without friction as implemented by (Heislitz et al, 1996), and (Sheu, 2004) in which the resultant motion is the same, but boundary conditions are easier to specify. (Jiang et al, 2009), (Bui and Ponthot, 2008) showed that there is almost no difference between the predictions of first and second approach and friction has to do with driving the material forward.…”

Section: Overviewmentioning

confidence: 99%

Micro-indentation based study on steel sheet degradation through forming and flattening: Toward a predictive model to assess cold recyclability

Falsafi

Demirci

2016

Materials & Design

View full text Add to dashboard Cite

Article history:In Cold Roll Forming (CRF) process sheet material undergo a complex set of deformation that entail complicated through thickness residual deformation. This paper, focuses on material behaviour in CRF processes, with regarding damage and material degradation. A roll forming process is taken as case study and experimental investigation using extensive microhardness mapping alongside FE simulation of the process are the basis of material damage study. Indentation on different cross-sectional cutting angles -45, 0, 45 has been performed to study the sensitivity to orientation and crystallographic texture. A 3D Finite Element simulation with emphasis on through-thickness variation of the plastic deformation was carried out, using multiple layers of solid elements representing the sheet. A smart approach to reduce computational cost was employed in MSC.Marc by implementing simulation of a master model of complete material with shell elements, followed by partial submodelling comprising solid elements in regions of interest. This cross-sectional hardness map was then converted to the corresponding equivalent plastic strain in the cross section for validation. The correlation factor between Hardness and yield stress was discussed.

show abstract

“…Several elements with unique properties have been tried to simulate the sheet metal bending process and springback behavior. Among the elements, four-node shell element [2][3][4][5][6][7] and eight-node solid element [8][9][10][11][12] are the most popular because of their respective outstanding advantages. In the last decade, reduced enhanced solid shell (RESS) element developed by Alves de Sousa [13][14][15], which has both advantages of shell element and solid element, has aroused a lot of interest.…”

Section: Introductionmentioning

confidence: 99%

Springback Simulation in Air Bending of Titanium Alloy Sheet Using Solid Shell Element

Fu¹,

Li²,

Sun³

et al. 2016

Proceedings of the 2015 4th International Conference on Sensors, Measurement and Intelligent Materials

View full text Add to dashboard Cite

Abstract. Accuracy improvement of springback prediction is a major concern in finite element simulation of sheet metal bending process, especially for the materials with high elastic recovery. This work adopts solid shell finite element for springback simulation and improves the simulation accuracy by means of rationalizing mesh discretization and through-thickness integration scheme. Meanwhile, air bending experiment of titanium alloy Ti-6Al-4V was carried out to examine the simulation result. Research results demonstrate that solid shell element has better performance than thick shell element in springback simulation. The accuracy can be improved evidently by extending the mesh refinement area to 2 times of sheet thickness from the bending corner. The optimal number of integration points varies with the bending radius and the limited error tolerance.

show abstract

Simulation of roll forming process with the 3-D FEM code PAM-STAMP

Cited by 102 publications

References 4 publications

Predicting plastic deformation and work hardening during V-band formation

Predicting plastic deformation and work hardening during V-band formation

Micro-indentation based study on steel sheet degradation through forming and flattening: Toward a predictive model to assess cold recyclability

Springback Simulation in Air Bending of Titanium Alloy Sheet Using Solid Shell Element

Contact Info

Product

Resources

About