Numerical Simulation for the Roll Forming Process of a Channel Steel

Abstract

In this study, finite element method is used to analyze the stress and strain distributions in various regions of a channel steel during the roll forming process, and reveal the deformation pattern of the channel steel. The results indicate that the deformation and thickness reduction of sheet metal mainly concentrates in the corner and the ends of web section, while it is insignificant in the channel edges and the central portion of the web. During the stable stage of roll forming process, the rolling force fluctuation in each pass is related to the change of forming angle in that pass. For the pass with the largest change of forming angle, the most significant fluctuation in rolling force is observed. It is also the pass that most probably causes quality issues to the final product. Finally, it is found that changing the forming angle distribution among all the passes cannot reduce the stress fluctuation among the passes. As such, the process optimization needs to be realized by other approaches.