Simulation of roll forming for U-shaped bent profiles

Abstract

Purpose. To develop an approach for simulating the roll forming process of U-shaped bent profiles using the QForm software package. Methodology. The study is based on the finite element method implemented in QForm. The process was simulated in a 3D environment, accounting for elastic–plastic deformation, using a single operation of the «Sheet Bulk Forming» type. A sequential forming scheme was implemented using 12 roll stands, which incorporated the elastic–plastic properties of the material. Appropriate boundary conditions were defined to replicate real technological parameters of the roll forming process. Results. The simulation yielded stress and strain distributions in the blank at various stages of its passage through the roll stands. It was found that maximum plastic strains occur in the bending zones, while the edge regions are predominantly subjected to tensile stresses. The simulation results are consistent with the physical nature of the bending process and confirm the validity of the proposed approach. Scientific Novelty. An adaptation of the QForm software package is proposed for simulating the roll forming of bent profiles, which is not covered by its standard modules. Simulation algorithm and boundary condition setup were developed, enabling the analysis of the stress–strain state of the blank during profile formation. Practical Significance. The results of the study can be used to optimize technological parameters of the roll forming process, reduce the likelihood of defect formation, and expand the functional capabilities of QForm in the field of sheet metal forming simulation. The proposed approach is valuable for technologists, engineers, designers, and researchers working in the field of metal forming.