Numerical simulation of special-shaped tube roll forming process based on precise control of adjacent angles
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(1. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China; 2. Shunde Innovation School, University of Science and Technology Beijing, Foshan 528399, Guangdong, China; 3. Institute of Artificial Intelligence, University of Science and Technology Beijing, Beijing 100083, China; 4. National Engineering Research Center of Flat Rolling Equipment, University of Science and Technology Beijing, Beijing 100083, China; 5. Jiangsu Durable Machinery Co., Ltd., Yangzhou 225000, Jiangsu, China)

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TG335.4

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    Abstract:

    The large deviation of adjacent concave and convex angles in multi-pass roll forming of P-shaped special-shaped tubes for automobile columns cannot meet the high-precision requirements. On the basis of the large elastic-plastic deformation theory, a 15-pass roll forming finite element model of P-shaped special-shaped tube was established by using the professional design software COPRA. Combined with the actual production process, the finite element simulation of the complete forming process was carried out, and it was found that the insufficient supply of the perimeter of the welded pipe and the uneven metal flow of the corners of the P-shaped special-shaped tube in the roll pass caused the large deviation of the adjacent concave and convex angles. Thus, a precise control method of adjacent angles was proposed based on simulation and production practice, which combines selecting the appropriate compression coefficient, assigning the appropriate section deformation, and correcting the roll shape. The finite element simulation of roll forming of the P-shaped special-shaped tube was carried out by the proposed method. Results showed that the cross-section of the simulated final product was basically the same as the design cross-section, the concave and convex angles were 90.5° and 89.9°, and the angle deviation was within the error range of ±1°. The metal flow was in place, so that the corner metal filled the roll pass, which improved the forming quality of the adjacent concave and convex angles of the P-shaped special-shaped tube. The proposed method achieved an increase of 33.84% and 36.70% in the accuracy of the adjacent concave and convex angles of the P-shaped special-shaped tube through industrial application, which can effectively improve the forming quality of the P-shaped special-shaped tube and provide basis for production practice.

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History
  • Received:May 19,2022
  • Revised:
  • Adopted:
  • Online: January 08,2023
  • Published:
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