[en] Cold roll forming modifies the mechanical properties of thin-walled profiles by strain hardening. The understanding of this phenomenon, which is rather good for profiles made of traditional construction steel, is mandatory for assessing the member resistance. Less information is however available for profiles made of materials exhibiting a pronounced degree of nonlinearity of the stress-strain curve such as high-strength and stainless steels. Current codes generally encounter difficulties for modelling this fabrication process because of the size of industrial mills. Indeed, accurate modelling of the continuous cold roll forming process using finite elements requires a huge number of elements leading to excessive CPU times. Therefore, modellers usually reduce the geometry of the formed sheet or increase the size of the finite elements, inducing a loss of accuracy in the results. In this work, the finite element software METAFOR is used to model cold roll forming of channel profiles made of high-strength and stainless steels. The numerical results, expressed in terms of corner strength enhancement versus radius–to–thickness ratio, are compared against an existing predictive model.
Disciplines :
Civil engineering Mechanical engineering
Author, co-author :
Rossi, Barbara ; Université de Liège - ULiège > Département Argenco : Secteur MS2F > Adéquat. struct. aux exig. de fonct.& perfor. techn.-écon.
Degée, Hervé ; Université de Liège - ULiège > Département ArGEnCo > Département ArGEnCo
Boman, Romain ; Université de Liège - ULiège > Département d'aérospatiale et mécanique > Département d'aérospatiale et mécanique
Language :
English
Title :
Numerical simulation of the Roll forming of thin-walled sections and evaluation of corner strength enhancement
M. Brunet, B. Lay, and P. Pol Computer aided design of roll-forming of channel sections J. Mater. Process. Technol. 60 1-4 1996 209 214 (Pubitemid 126383281)
M. Brunet, S. Mguil, and P. Pol Modelling of a roll-forming process with a combined 2D and 3D FEM code J. Mater. Process. Technol. 80-81 1998 213 219 (Pubitemid 128639005)
L. Grisard, Modélisation bidimensionnelle de la mise à forme des tôles par la méthode des éléments finis, Ph.D. Thesis, Université de Liège, 1995.
C. Liu, Y. Zhou, and W. Lu Numerical simulation of roll-forming by b-spline finite strip method J. Mater. Process. Technol. 60 1-4 1996 215 218 (Pubitemid 126383282)
Z.-W. Han, C. Liu, W.-P. Lu, and L.-Q. Ren Simulation of a multi-stand roll-forming process for thick channel section J. Mater. Process. Technol. 127 3 2002 382 387
F. Heislitz, H. Livatyali, M.A. Ahmetoglu, G.L. Kinzelb, and T. Altan Simulation of roll forming process with the 3-D FEM code PAM-STAMP J. Mater. Process. Technol. 59 1-2 1996 59 67 (Pubitemid 126369416)
M.S. Tehrani, P. Hartley, H.M. Naeini, and H. Khademizadeh Localised edge buckling in cold roll-forming of symmetric channel section Thin-Walled Struct. 44 2 2006 184 196
W.J.T. Daniel, P.A. Meehan, Implicit finite element study of non-steady effects in cold roll forming, in: Proceedings of ACAM - the Fifth Australasian Congress on Applied Mechanics, Brisbane, Australia, 10-12 December 2007.
Q.V. Bui, L. Papeleux, and J.-P. Ponthot Numerical simulation of springback using enhanced assumed strain elements J. Mater. Process. Technol. 153-154 2004 314 318
Q.V. Bui, R. Boman, L. Papeleux, P. Wouters, R. Kergen, G. Daolio, P. Flores, A.-M. Habraken, J.-P. Ponthot, Springback and twist prediction of roll formed parts, in: Proceedings of IDDRG 2006: International Deep Drawing Research Group Conference, on CDROM, Porto, June 17-19, 2006.
Q. Bui, and J.-P. Ponthot Numerical simulation of cold roll-forming processes J. Mater. Process. Technol. 202 1-3 2008 275 282 (Pubitemid 351626973)
J.-P. Ponthot, Traitement unifié de la Mécanique des Milieux Continus solides en grandes transformations par la méthode des éléments finis, Ph.D.Thesis, University of Liège, 1995.
H. Sukmoo, L. Seungyoon, and K. Naksoo A parametric study on forming length in roll forming J. Mater. Process. Technol. 113 1-3 2001 774 778
N. Kim, B. Kang, and S. Lee Prediction and design of edge shape of initial strip for thick tube roll forming using finite element method J. Mater. Process. Technol. 142 2 2003 479 486
M. Sheikh, and R. Palavilayil An assessment of finite element software for application to the roll-forming process J. Mater. Process. Technol. 180 1-3 2006 221 232 (Pubitemid 44314087)
R. Boman, L. Papeleux, Q.V. Bui, and J.-P. Ponthot Application of the Arbitrary Lagrangian Eulerian formulation to the numerical simulation of cold roll forming process J. Mater. Process. Technol. 177 2006 621 625 (Pubitemid 44038336)
R. Boman, and J.-P. Ponthot Application of the arbitrary Lagrangian Eulerian Formalism to stationary roll forming simulations Adv. Mater. Res. 189-193 2011 1827 1833
A. Depauw, D. Hérisson, R. Boman, R. Kergen, Roll forming of ultra high strengh steels: progresses in experimental and modelling knowledge, in: Proceedings of Rollform 2009, Bilbao, Spain, 2009, pp. 101-108.
Q.V. Bui, L. Papeleux, R. Boman, J.-P. Ponthot, P. Wouters, R. Kergen, G. Daolio, Numerical simulation of cold roll forming process, in: Proceedings of ESAFORM 2005: the 8th Esaform Conference on Material Forming, 2005, pp. 141-144.
K. Karren Corner properties of cold-formed steel shapes J. Struct. Div. (ASCE) 93 1967 401 432
J.S. Coetzee, G.J. Van Den Berg, P. Van den Merwe, The effect of work hardening and residual stresses due to cold work of forming on the strength of cold-formed stainless steel lipped channel section, in: W.W. Yu, R.A. LaBoube (Eds.), Proceedings of the Tenth International Specialty Conference on Cold-Formed Steel Structures, University of Missouri-Rolla, Rolla, October 1990.
G.J. Van Den Berg, P. Van der Merwe, Prediction of corner mechanical properties for stainless steels due to cold forming, in: W.W. Yu (Ed.), Proceedings of the Eleventh International Specialty Conference on Cold-Formed Steel Structures, St. Louis, October 1992.
L. Gardner, and D.A. Nethercot Experiments on stainless steel hollow sections - part 1: material and cross-sectional behavior J. Constr. Steel Res. 60 9 2004 1291 1318 (Pubitemid 38688731)
L. Gardner, and D.A. Nethercot Experiments on stainless steel hollow sections - part 2: member behavior of columns and beams J. Constr. Steel Res. 60 9 2004 1319 1332 (Pubitemid 38688732)
M. Ashraf, Structural Stainless Steel Design: Resistance Based on Deformation Capacity, Ph.D Thesis, London, Imperial College of London, 2006.
S. Afshan, B. Rossi, L. Gardner, Strength Enhancements in Cold-formed Structural Sections - Part I: Material Testing, J. Constr. Steel Res., 10.1016/j.jcsr.2012.12.008 in press.
B. Rossi, S. Afshan, L. Gardner, Strength Enhancements in colD-formed Structural Sections - Part II: Predictive moDels, J. Constr. Steel Res., 10.1016/j.jcsr.2012.12.007 in press.
J. Rondal Residual stresses in cold-rolled profiles Constr. Build. Mater. 1 3 1987 150 164
R. Cruise, The Influence of Production Routes on the Behaviour of Stainless Steel Structural Members, Ph.D Thesis, Imperial College London, 2007.
W.M. Quach, Residual Stresses in Cold Formed Steel Sections and their Effect on Column Behaviour, Ph.D Thesis, The Hong Kong Polytechnic University, 2005.
B.W. Schafer, and T. Peköz Computational modelling of cold-formed steel: characterizing geometric imperfections and residual stresses J. Constr. Steel Res. 47 3 1998 193 210 (Pubitemid 128429296)
B. Rossi, R. Boman, H. Degée, Effects of the roll forming process on the mechanical properties of thin-walled sections made of non linear metallic materials, in: D. Dubina, V. Ungureanu (Eds.), Proceedings of the 6 th International Conference on Thin Walled Structures, Timisoara, September 2011.
B. Rossi Mechanical behavior of ferritic grade 3Cr12 stainless steel - part 2: yield locus and hardening laws Thin-walled Struct. 48 7 2010 553 560
W.M. Quach, J.G. Teng, and K.F. Chung Residual stresses in press-braked stainless steel sections, II: press-braking operations J. Constr. Steel Res. 68 8-9 2009 1803 1815
C.C. Weng, and R.N. White Residual-stresses in cold-bent thick steel plates J. Struct. Eng. 116 1 1990 24 39
B. Rossi, Mechanical Properties, Residual Stresses and Structural Behavior of Thin-walled Stainless Steel Profiles, Ph.D Thesis, University of Liège, 2008.
J. Chung, and G.M. Hulbert A time integration algorithms for structural dynamics with improved numerical dissipations: the generalized-a Method J. Appl. Mech. 60 1993 371 375 (Pubitemid 23679960)
R.B. Cruise, and L. Gardner Strength enhancements induced during cold forming of stainless steel sections J. Constr. Steel Res. 64 11 2008 1310 1316
P. Flores, Development of Experimental Equipment and Identification Procedures for Sheet Metal Constitutive Laws, Ph.D. Thesis, University of Liège, Liège, 2006.
European Committee for Standardization. Eurocode 3: Design of Steel Structures - Part 1-1: General Rules and Rules for Buildings, CEN-2005, 2005.
European Committee for Standardization. Eurocode 3: Design of Steel Structures - Part 1-3: General Rules - Supplementary Rules for Cold-Formed Members and Sheeting, CEN-2006, 2006.
M. Ashraf, L. Gardner, and D.A. Nethercot Strength enhancement of the corner regions of stainless steel cross-sections J. Constr. Steel Res. 61 1 2005 37 52
