فصلنامه علمی کارافن

فصلنامه علمی کارافن

مطالعه برگشت فنری پروفیل‌های سوراخ دار در فرایند شکل‌دهی غلتکی سرد

نوع مقاله : مقاله پژوهشی (کاربردی)

نویسندگان
1 دانشجوی دکتری، گروه مهندسی مکانیک، دانشگاه تربیت مدرس، تهران، ایران.
2 استاد، گروه مهندسی مکانیک، دانشگاه تربیت مدرس، تهران، ایران.
3 استادیار، گروه مهندسی مکانیک، دانشگاه کاشان، کاشان، ایران.
4 دانشیار، گروه مهندسی مکانیک، دانشگاه صنعتی قم، قم، ایران.
5 دانشجوی کارشناسی ارشد، گروه مهندسی مکانیک، دانشگاه تربیت مدرس، تهران، ایران.
چکیده
فرایند شکل‌دهی غلتکی سرد یکی از فرایندهای متداول شکل‌دهی پروفیل‌های فلزی در صنعت است. به دلیل ماهیت تغییر شکل خمشی که در ورق بر اثر فرایند شکل‌دهی غلتکی سرد رخ می‌دهد، یکی از مهم‌ترین عیوب غیرقابل‌اجتناب در محصول عیب برگشت فنری ‌است. در این مقاله به تأثیر وجود سوراخ و موقعیت آن بر روی میزان برگشت فنری ایجادشده به روش تجربی و عددی پرداخته‌شده است. جهت بررسی اثر موقعیت سوراخ از سه پروفیل با مقطع کانالی از جنس St12 با ضخامت 1 میلی‌متر به‌صورت بدون سوراخ، دارای سوراخ دایره‌ای در مرکز ناحیه خم و دارای سوراخ بر روی بال پروفیل در نزدیکی ناحیه خم استفاده شد. شکل‌دهی غلتکی سرد در سه ایستگاه با الگوی شعاع خم ثابت با خم‌کاری 15 درجه در هر ایستگاه شکل‌دهی و حل عددی با استفاده از نرم‌افزار اجزای محدود آباکوس انجام شد. نتایج حاکی از آن است که میان میزان برگشت فنری و موقعیت سوراخ ارتباطی وجود دارد به این صورت که میزان برگشت فنری در پروفیل دارای سوراخ روی ناحیه خم 9 درصد بیشتر از پروفیل بدون سوراخ و در پروفیل دارای سوراخ در نزدیکی ناحیه خم 16 درصد کمتر از پروفیل بدون سوراخ است. همچنین طبق نتایج اجزاء محدود مشاهده شد که میزان کرنش مومسان معادل وارده به ناحیه خم پروفیل دارای سوراخ روی ناحیه خم 20 درصد کمتر و در پروفیل دارای سوراخ در نزدیک ناحیه خم 16 درصد بیشتر از پروفیل بدون سوراخ است که می‌تواند علت اختلاف مشاهده شده در برگشت فنری را توجیه کند.
کلیدواژه‌ها
موضوعات

عنوان مقاله English

A Study on Spring-back of Pre-punched Profiles in Cold Roll Forming Process

نویسندگان English

Saeid Hajiahmadi 1
Hassan Moslemi Naeini 2
Hossein Talebi-Ghadikolaee 3
Rasoul Safdarian 4
Ali Zeinolabedin Beygi 5
1 Phd Student, Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran.
2 Professor, Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran.
3 Assistant Professor, Department of Mechanical Engineering, University of Kashan, Kashan, Iran.
4 Associate Professor, Department of Mechanical Engineering, Qom University of Technology, Qom, Iran.
5 MSc Student, Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran.
چکیده English

The cold roll forming is one of the common processes to form metal profiles in the industry. Due to the nature of the bending deformation in cold roll forming process, spring-back is one of the most important defects. In order to compensate the spring-back, the amount of spring-back must be correctly predicted. In this article, the effect of the hole and its position on the spring-back has been investigated by experimental and numerical methods. three channel section profiles made of St12 and thickness of 1 mm, without hole, with circular holes on the bend area and with holes on the flange were used. Cold roll forming was done in three stations with a fixed bending radius pattern with 15 degree bending in each forming station and numerical solution using Abaqus finite element software. The results indicate that there is a relationship between the amount of spring-back and the position of the hole in such a way that the amount of spring-back in hole on the bend area profile is 9% more than the hole-less profile and in hole on the flange profile is 16% less than hole-less profile. Also, according to finite elements results, it was observed that the amount of equivalent strain in the bend area of the profile with holes on the bend area is 20% less and in the profile with holes near the bend area is 16% more than the profile without holes, which can justify the difference observed in the amount of spring-back.

کلیدواژه‌ها English

Cold Roll Forming
Spring-back
Pre-punched Sheet
Finite Element Simulation
[1] Talebi-Ghadikolaee, H., Elyasi, M., Dadgar Asl, Y., Zeinolabedin Beygi, A., & Davoudi, M. (2022). Feasibility of forming U-shaped microchannels by the flexible-die forming process. Karafan Quarterly Scientific Journal, 19(3), 53-70. https://doi.org/10.48301/ks sa.2022.336972.2063
[2] Safdarian, R., & Pournouri, H. (2019). Experimental and numerical study of hydro-mechanical deep drawing of 2024 aluminum alloy sheet at elevated temperatures. Materials Research Express, 6(8), 086505. https://doi.org/10.1088/2053-1591/ab1ae5
[3] Khatir, F. A., Barzegari, M. M., Talebi-Ghadikolaee, H., & Seddighi, S. (2021). Integration of design of experiment and finite element method for the study of geometrical parameters in metallic bipolar plates for PEMFCs. International Journal of Hydrogen Energy, 46(79), 39469-39482. https://doi.org/10.1016/j.ijhydene.2021.09.161
[4] Deilami Azodi, H., Rezaei, S., Zeinolabedin Beygi, A., & Badparva, H. (2022). Investigation of Parameters Influencing Forming Force and Thickness Distribution in Single Point Incremental Forming of AA3105-St12 Two-Layer Sheet. Iranian Journal of Materials Forming, 9(2), 46-57. https://doi.org/10.22099/IJMF.2022.42993.1215
[5] Safdarian, R., & Kord, A. (2019). Experimental investigation of effective parameters in the tube rotary draw bending process. Materials Research Express, 6(6), 066531. ht tps://doi.org/10.1088/2053-1591/ab0c36
[6] Halmos, G. T. (2005). Roll forming handbook. Crc Press. https://doi.org/10.1201/978142 0030693
[7] Liang, C., Li, S., Liang, J., & Li, J. (2021). Method for Controlling Edge Wave Defects of Parts during Roll Forming of High-Strength Steel. Metals, 12(1), 53. https://doi.or g/10.3390/met12010053
[8] Safdarian, R., & Naeini, H. M. (2015). The effects of forming parameters on the cold roll forming of channel section. Thin-Walled Structures, 92, 130-136. https://doi.org/10. 1016/j.tws.2015.03.002
[9] Tajik, Y., Naeini, H. M., Tafti, R. A., & Bidabadi, B. S. (2018). A strategy to reduce the twist defect in roll-formed asymmetrical-channel sections. Thin-Walled Structures, 130, 395-404. https://doi.org/10.1016/j.tws.2018.05.013
[10] Moneke, M., & Groche, P. (2021). The origin of end flare in roll formed profiles. International Journal of Material Forming, 14(6), 1439-1461. https://doi.org/10.1007/s12289-021-0164 0-w
[11] Talebi-Ghadikolaee, H., Moslemi Naeini, H., Rabiee, A. H., Zeinolabedin Beygi, A., & Alexandrov, S. (2022). Experimental-numerical analysis of ductile damage modeling of aluminum alloy using a hybrid approach: ductile fracture criteria and adaptive neural-fuzzy system (ANFIS). International Journal of Modelling and Simulation, 1-16. https:// doi.org/10.1080/02286203.2022.2121675
[12] Talebi-Ghadikolaee, H., Moslemi Naeini, H., Talebi Ghadikolaee, E., & Mirnia, M. J. (2022). Predictive modeling of damage evolution and ductile fracture in bending process. Materials Today Communications, 31, 103543. https://doi.org/10.1016/j.mtcomm.2022 .103543
[13] Banabic, D. (2010). Sheet metal forming processes: constitutive modelling and numerical simulation. Springer Science & Business Media. https://doi.org/10.1007/978-3-540-88113-1
[14] Abvabi, A., Mendiguren, J., Rolfe, B. F., & Weiss, M. (2014). Springback investigation in roll forming of a V-section. Applied mechanics and materials, 553, 643-648. https ://doi.org/10.4028/www.scientific.net/AMM.553.643  
[15] Su, C., Liu, J., Zhao, Z., Lou, S., Wang, R., & Yang, L. (2020). Research on roll forming process and springback based on five-boundary condition forming angle distribution function. Journal of Mechanical Science and Technology, 34(12), 5193-5204. https: //doi.org/10.1007/s12206-020-1121-4
[16] Groche, P., Beiter, P., & Henkelmann, M. (2008). Prediction and inline compensation of springback in roll forming of high and ultra-high strength steels. Production Engineering, 2(4), 401-407. https://doi.org/10.1007/s11740-008-0131-3
[17] Jiao-Jiao, C., Jian-Guo, C., Qiu-Fang, Z., Jiang, L., Ning, Y., & Rong-guo, Z. (2020). A novel approach to springback control of high-strength steel in cold roll forming. The International Journal of Advanced Manufacturing Technology, 107(1), 1793–1804. https://doi.org/10.1007/s00170-020-05154-8
[18] Badr, O. M., Rolfe, B., Zhang, P., & Weiss, M. (2017). Applying a new constitutive model to analyse the springback behaviour of titanium in bending and roll forming. International Journal of Mechanical Sciences, 128-129, 389-400. https://doi.org/10.1016/j.ijmecsci.2 017.05.025
[19] Liu, X.-l., Cao, J.-g., Huang, S.-x., Yan, B., Li, Y.-l., & Zhao, R.-g. (2020). Experimental and numerical prediction and comprehensive compensation of springback in cold roll forming of UHSS. The International Journal of Advanced Manufacturing Technology, 111(3), 657-671. https://doi.org/10.1007/s00170-020-06133-9
[20] Naofal, J., Naeini, H. M., & Mazdak, S. (2019). Effects of hardening model and variation of elastic modulus on springback prediction in roll forming. Metals, 9(9), 1005. https ://doi.org/10.3390/met9091005
[21] Bidabadi, B. S., Naeini, H. M., Tafti, R. A., & Barghikar, H. (2016). Experimental study of bowing defects in pre-notched channel section products in the cold roll forming process. The International Journal of Advanced Manufacturing Technology, 87(1), 997-1011. https://doi.org/10.1007/s00170-016-8547-y
[22] Farsi, M. A., Arezoo, B., Alizadeh, V., & Mirzaee, S. (2011). The study of spring-back in wipe-bending processes for perforated components. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 225(11), 2007-2014. https://doi.org/10.1177/0954405411403253
[23] Nasrollahi, V., & Arezoo, B. (2012). Prediction of springback in sheet metal components with holes on the bending area, using experiments, finite element and neural networks. Materials & Design (1980-2015), 36, 331-336. https://doi.org/10.1016/j.matdes.2011.1 1.039
[24] Poursafar, A., Saberi, S., Tarkesh, R., Vahabi, M., & Fesharaki, J. J. (2022). Experimental and mathematical analysis on spring-back and bowing defects in cold roll forming process. International Journal on Interactive Design and Manufacturing, 16(2), 531–543. https://doi.org/10.1007/s12008-021-00818-5
[25] Zeinali, M. S., Naeini, H. M., Talebi-Ghadikolaee, H., & Panahizadeh, V. (2022). Numerical and Experimental Investigation of Fracture in Roll Forming Process Using Lou–Huh Fracture Criterion. Arabian Journal for Science and Engineering, 47, 15591–15602. htt ps://doi.org/10.1007/s13369-022-06662-3
[26] Mohammdi Najafabadi, H., Moslemi Naeini, H., Safdarian, R., Kasaei, M. M., Akbari, D., & Abbaszadeh, B. (2019). Effect of forming parameters on edge wrinkling in cold roll forming of wide profiles. The International Journal of Advanced Manufacturing Technology, 101(1), 181-194. https://doi.org/10.1007/s00170-018-2885-x
[27] Shirani Bidabadi, B., Moslemi Naeini, H., Safdarian, R., & Barghikar, H. (2022). Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 236(10), 1380-1392. https://doi.org/https://doi.or g/10.1177/09544054221076628
[28] Lindgren, M. (2008, June 16-18). Validation of finite element model of roll forming. International Deep Drawing Research Group  2008 International Conference, Olofström, Sweden. https://www.researchgate.net/publication/29751706_Validation_of_finite _element_model_of_roll_forming
دوره 20، شماره 1 - شماره پیاپی 61
فنی و مهندسی
بهار 1402
صفحه 193-216

  • تاریخ دریافت 06 آذر 1401
  • تاریخ بازنگری 25 اسفند 1401
  • تاریخ پذیرش 21 فروردین 1402