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Numerical model accuracy of solid and shell elements when simulating the roll forming process

conference contribution
posted on 2012-01-01, 00:00 authored by Jason Jiao, Bernard RolfeBernard Rolfe, Matthias WeissMatthias Weiss
Conventional roll forming is a common manufacturing process that incrementally bends a sheet into a desired cross-section by passing it though successive sets of rolls. Finite Element Analysis (FEA) is increasingly used in roll forming process design, but generally incurs large computational costs due to the specific nature of the process involving the forming of continuous sheet over multiple stands. This paper analyses the model accuracy achievable when using solid and shell elements for roll forming simulations in Abaqus. To establish the reliability of the numerical models, convergence and sensitivity studies were performed with each element type to determine the appropriate mesh densities and element properties. The simulation results were compared to the experimental results for bow, springback and longitudinal strains. The results indicate that shell elements with proper meshing strategy lead to better model accuracy compared to solid elements and this is achieved with significantly reduced computational costs.

History

Event

Advances in Materials & Processing Technologies. Conference (15th : 2012 : Wollongong, New South Wales)

Series

AMPT: Advances in Materials & Processing Technologies Conference

Pagination

1 - 7

Publisher

University of Wollongong

Location

Wollongong, New South Wales

Place of publication

Wollongong, N.S.W.

Start date

2012-09-23

End date

2012-09-26

Language

eng

Publication classification

E Conference publication; E1 Full written paper - refereed

Copyright notice

2012, The Authors

Title of proceedings

AMPT 2012 : Proceedings of the 15th Advances in Materials & Processing Technologies Conference

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