New Advances in Numerical Simulation of Stationary Processes using Arbitrary Lagrangian Eulerian Formalism. Application to Roll Forming Process

2010 ◽  
Author(s):  
R. Boman ◽  
J.-P. Ponthot ◽  
F. Barlat ◽  
Y. H. Moon ◽  
M. G. Lee
Keyword(s):  
Numerical Simulation ◽  
Roll Forming ◽  
Stationary Processes ◽  
Arbitrary Lagrangian Eulerian ◽  
Forming Process ◽  
Roll Forming Process

Computerized Numerical Simulation of Roll-Forming Process

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 239-242 ◽  
Author(s):  
Manabu Kiuchi ◽  
Kenji Abe ◽  
Ryu Onodera
Keyword(s):  
Numerical Simulation ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

scholarly journals Numerical Simulation of the Roll Forming Process of Aluminum Folded Micro-channel Tube

2016 ◽  
Vol 734 ◽  
pp. 032016 ◽  
Author(s):  
Tianxia Zou ◽  
Ning Zhou ◽  
Yinghong Peng ◽  
Ding Tang ◽  
Dayong Li
Keyword(s):  
Numerical Simulation ◽  
Roll Forming ◽  
Micro Channel ◽  
Forming Process ◽  
Channel Tube ◽  
Roll Forming Process

Continuous Roll Forming Simulation Using Arbitrary Lagrangian Eulerian Formalism

2011 ◽  
Vol 473 ◽  
pp. 564-571 ◽  
Author(s):  
Romain Boman ◽  
Jean Philippe Ponthot
Keyword(s):  
Numerical Simulation ◽  
Rolling Direction ◽  
Initial Guess ◽  
Roll Forming ◽  
Arbitrary Lagrangian Eulerian ◽  
The Finite Element Method ◽  
Forming Simulation ◽  
Element Size ◽  
Cold Roll ◽  
Classical Lagrangian

Due to the length of the mill, accurate modelling of stationary solution of continuous cold roll forming by the finite element method using the classical Lagrangian formulation usually requires a very large mesh leading to huge CPU times. In order to model industrial forming lines including many tools in a reasonable time, the sheet has to be shortened or the element size has to be increased leading to inaccurate results. On top of this, applying loads and boundary conditions on this smaller sheet is usually more difficult than in the continuous case. Moreover, transient dynamic vibrations, which are unnecessarily computed, may appear when the sheet hits each tool, decreasing the convergence rate of the numerical simulation. Beside this classical Lagrangian approach, an alternative method is given by the Arbitrary Lagrangian Eulerian (ALE) formalism which consists in decoupling the motion of the material and the mesh. Starting from an initial guess of the sheet geometry between the rolls, the numerical simulation is performed until the stationary state is reached with a mesh, the nodes of which are fixed in the rolling direction but are free to move on perpendicular plane, following the geometrical boundary of the sheet. The whole forming line can then be modelled using a limited number of brick and contact elements because the mesh is only refined near the tools where bending and contact occur. In this paper, ALE results are compared to previous Lagrangian simulations and experimental measurement on a U-channel, including springback. Advantages of the ALE method are finally demonstrated by the simulation of a tubular rocker panel on a 16-stands forming mill.

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