A novel roll-die forming technology and its FEM simulation

• DOI: 10.1016/j.proeng.2017.10.887
• Publication Date: 2017-11-15T12:09:46Z
• Authors: Yu Yan; Hongzheng Nie; Haibo Wang; Qiang Li; Yanfu Liu
• Keywords: 0203 mechanical engineering; 02 engineering and technology

Abstract A new flexible roll forming technology named “roll-die forming” is developed. The part with variable heights along the length direction can be manufactured with the roll-die forming method. Roll-die forming process is a new plastic forming process, combining movable rollers and a fixed die. In other words, the new forming technology is the combination of conventional stamping and roll forming technologies. During roll-die forming process, the conjugate relation between the die and the roller is fitted in real time. The complex movements of the rollers are driven by servo motors. The new forming technology is presented in detail in this study. An automobile part with variable height along the length direction is successfully formed with the new developed forming technology. Besides, the corresponding FEM simulation of the forming process is carried out with ABAQUS commercial software. The FEM simulation and experimental results are compared with each other. It shows that the established FEM simulation model can predict forming process reasonably and can provide support for further optimization of the new developed forming technology.