Abstract
In the present study, a five-boundary conditional distribution function of the forming angle is proposed. The stress, strain, and springback of a sheet in roll-forming process under three different angle distribution functions are studied. Furthermore, effects of forming angle increment, sheet thickness, and material yield strength on stress, strain distribution, and springback of sheet during roll forming are studied under optimized forming angle. The results demonstrate that stress, strain, and springback of each pass based on increment of forming angle under five-boundary condition during roll forming are less than those achieved by other forming angle distribution methods. The stress and strain in the bending zone increase with increase in the sheet thickness. After roll forming, the springback angle decreases with the increase of sheet thickness, increases with the increase of forming angle and material yield strength. However, springback angle can be effectively reduced by increasing the number of passes or correction rolls.
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Abbreviations
- N :
-
The number of forming passes
- θ 0 :
-
The final forming angle of the vertical edge
- H :
-
The length of the vertical edge
- I :
-
The forming pass number
- θ i :
-
The forming angle
- Δθ i :
-
The forming angle increment
- FAI :
-
Forming angle increment (distribution method)
- FAI.5B :
-
Five-boundary condition forming angle distribution function
- FAI.4B :
-
Four-boundary condition forming angle distribution function
- FAI.10° :
-
10° increment of forming angle
- S.T. :
-
Sheet thickness
- PEEQ :
-
Equivalent plastic strain
- S :
-
Stress
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Acknowledgments
The authors would like to acknowledge the financial support provided by the National Natural Science Foundation of China (Grant No.51305241), National Natural Science Foundation of China (Grant No.51705295), Natural Science Foundation of Shandong Province (CN) (ZR2018MEE022), and Youth Innovation Team Development Plan of Colleges and Universities in Shandong province (2019KJB015).
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Chunjian Su received his M.Sc. (2004) and Ph.D. (2007) in Material Processing Engineering from Yanshan University in China. Now he is a Professor of Mechanical Engineering and Automation at Mechanical and Electronic Engineering Department, Shandong University of Science and Technology. His current research interests include different aspects of artificial intelligence and electromechanical systems.
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Su, C., Liu, J., Zhao, Z. et al. Research on roll forming process and springback based on five-boundary condition forming angle distribution function. J Mech Sci Technol 34, 5193–5204 (2020). https://doi.org/10.1007/s12206-020-1121-4
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DOI: https://doi.org/10.1007/s12206-020-1121-4