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Simulation and Experimental Study on Roll-Forming Limit of Cup

Roll forming can improve the material utilization rate and production efficiency of cups with a curved rotary profile, but there is no basis for the determination of forming limit. The DEFORM-3D software was used to simulate the roll forming of cups. The influence of the billet wall thickness and bo...

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Autores principales: Zhang, Baohong, Ning, Shengpeng, Wei, Zeng, Duan, Yali, Li, Xubin, Yang, Yongbiao
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8877326/
https://www.ncbi.nlm.nih.gov/pubmed/35207822
http://dx.doi.org/10.3390/ma15041279
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author Zhang, Baohong
Ning, Shengpeng
Wei, Zeng
Duan, Yali
Li, Xubin
Yang, Yongbiao
author_facet Zhang, Baohong
Ning, Shengpeng
Wei, Zeng
Duan, Yali
Li, Xubin
Yang, Yongbiao
author_sort Zhang, Baohong
collection PubMed
description Roll forming can improve the material utilization rate and production efficiency of cups with a curved rotary profile, but there is no basis for the determination of forming limit. The DEFORM-3D software was used to simulate the roll forming of cups. The influence of the billet wall thickness and bottom thickness, coefficient of friction, radius of roller, and the fillet radius of the punch on the forming limit was studied, and the damage value and velocity vector were analyzed. The results showed that the forming limit of the billet’s wall thickness in roll forming for a cup is about 62%. With the increase of the ratio of the formed cup’s wall thickness to the billet’s bottom thickness, the forming limit of wall thickness will be slightly reduced. A larger radius of roller, fillet radius of punch, and friction coefficient between punch and billet and a smaller friction coefficient between roller and billet are good for decreasing the damage value and improving the roll-forming limit. According to the numerical simulation results, the roll-forming limit diagram of cups is established, and the accuracy of the forming limit diagram is verified by experiments.
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spelling pubmed-88773262022-02-26 Simulation and Experimental Study on Roll-Forming Limit of Cup Zhang, Baohong Ning, Shengpeng Wei, Zeng Duan, Yali Li, Xubin Yang, Yongbiao Materials (Basel) Article Roll forming can improve the material utilization rate and production efficiency of cups with a curved rotary profile, but there is no basis for the determination of forming limit. The DEFORM-3D software was used to simulate the roll forming of cups. The influence of the billet wall thickness and bottom thickness, coefficient of friction, radius of roller, and the fillet radius of the punch on the forming limit was studied, and the damage value and velocity vector were analyzed. The results showed that the forming limit of the billet’s wall thickness in roll forming for a cup is about 62%. With the increase of the ratio of the formed cup’s wall thickness to the billet’s bottom thickness, the forming limit of wall thickness will be slightly reduced. A larger radius of roller, fillet radius of punch, and friction coefficient between punch and billet and a smaller friction coefficient between roller and billet are good for decreasing the damage value and improving the roll-forming limit. According to the numerical simulation results, the roll-forming limit diagram of cups is established, and the accuracy of the forming limit diagram is verified by experiments. MDPI 2022-02-09 /pmc/articles/PMC8877326/ /pubmed/35207822 http://dx.doi.org/10.3390/ma15041279 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Zhang, Baohong
Ning, Shengpeng
Wei, Zeng
Duan, Yali
Li, Xubin
Yang, Yongbiao
Simulation and Experimental Study on Roll-Forming Limit of Cup
title Simulation and Experimental Study on Roll-Forming Limit of Cup
title_full Simulation and Experimental Study on Roll-Forming Limit of Cup
title_fullStr Simulation and Experimental Study on Roll-Forming Limit of Cup
title_full_unstemmed Simulation and Experimental Study on Roll-Forming Limit of Cup
title_short Simulation and Experimental Study on Roll-Forming Limit of Cup
title_sort simulation and experimental study on roll-forming limit of cup
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8877326/
https://www.ncbi.nlm.nih.gov/pubmed/35207822
http://dx.doi.org/10.3390/ma15041279
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