Simulation and design of multiple-station rolling forming for U-section steel bar

The simulation and design of continuous multiple-station roll forming process for the U-section steel bar has been accomplished by the application of CAE software-DEFORMTM. The limitation of element number has been overcome by considering a 120mm short strip that is being run through all the stations as a means for simulating the actual process for continuous rolling forming in the steel fabrication plant. Basically, this study has achieved viable results for the optimization of design of the operation process. The major parameters are: roller gap fixed at 0.30mm, rolling speed at 20 rad/sec and the separate deployment of 6, 9, 12 stations. The effects of stress and strain of the strip are considered, involving two cases of simulation based separately on (A) one single station and (B) two stations. The model of case (B) seems to be matchfully closer to the practical process than case (A). From the result of case (B), the stress for 12-station process is noted to be the smallest, 9-station process being intermediate and 6-station process giving the largest stress. Even though the situation of fewer stations provides the advantage of large savings for plant installation and shorter duration for forming operation, the highest stress and strain for the 6-station process will cause wrinkles on lateral sides, not found on 9-station and 12-station situations. Therefore, the 9-station process is thus shown to be a more suitable design than 12-station process, giving the benefit of smaller stresses as well as stretching and twisting in deformation. The progressive angles for 12-station are 7.5deg;; 10° for 9-station and the highest value of 15° for the 6-station process.