Cold Roll Forming is the process of running a flat sheet of material through a series of rollers, known as stands, to produce three - dimensional sections. This thesis aims to produce a Finite Element Model Simulation of Cold-Roll Forming process, particularly to the application LiteSteel Beam™ and 120 Nominal Bore Schedule 40 pipe as produced by Smorgon Steel Ltd. This simulation will then be used to investigate relationships between various operation parameters, including band angle and misalignment. This thesis is a component of a larger project, whose aim is to automate the process of Cold Roll Forming.
Finite Element Models of formed materials can help in the prediction of section properties particularly in developing and maintaining tolerances, as well as quality control issues, such as shape and edge crippling. The principle challenge associated with Finite Element Modelling of Cold Roll Forming is the non-linearity of the model, caused by the bulk plastic deformation, time dependence and the inclusion of contact in the model. The software to be used, ABAQUS, was chosQ11 for its ability to handle non-linear, time-dependant problems.
This thesis has a particular focus of the LiteSteel™ Beam product produced by Smorgon Steel Ltd. This has the potential to produce outcomes that may benefit the automation of cold roll forming, including relations involving damping force and rolling torque. Operational Advantages can also be gained, with an accurate knowledge and control of section properties, chiefly tolerances and the effects of strain hardening.
A skeleton model was produced, using a relatively simple geometry to determine the best method of implementing the simulation. Numerous outcomes from this step, such as numerical implementation, contact method and friction formulations were then used for more involved cold roll forming simulations.
Simulations were then conducted for both LiteSteel™ Beam, and 120 nominal Bore pipe. While modelling of the LiteSteel™ beam was largely unsuccessful, the modelling of 1201NB pipe was successful, and avenues such as residual stress, strain effects, and the detrimental effects of misalignment were explored.