About us

This resource is devoted to the finite-element analysis in LS-DYNA environment.

We are solving the tasks on strength, shaping, breaking, optimization and lots of others using advanced computer technologies.

Roll Forming

This example illustrates finite-element solution of the classic task of metal forming. In this case channel type bar shaping from a steel strip in rotating roll calibers is modeled. Usually the main purpose of such modeling is analysis of rough part material mode of deformation in the process of shaping. Results of such analysis are used for prevention (or reduction) of all sorts of shape malformation. There is a possibility to optimize in short terms the whole technological process as well as its separate stages without any expensive full-scale testing.

The main complexity upon such tasks solution is correct load and boundary conditions application, which should as much as possible approximate the computer emulation to the real processing. Another important problem is the mathematical model of the material, which should be able to reflect all the diversity of the physical-mechanical properties of the real prototype model (cold work hardening, springing, etc.). Specially emphasized in the process of mathematical model creation for solving this task is finite-element grid. Thickening it in the supposed problem zones (angular zone, shape edge, etc.) and rarefication of the grid in relatively «calm» zones (base, platform middle surface) in our case let us decrease the total amount of deformed SHELL elements of the rough part model down to 75000 and abandon mass scaling, so far improving the modeling results.

Roll tool and auxiliary equipment models were also created with the help of SHELL-elements, but their deformation behavior being not considered in this task, the model of «absolute rigid body» was taken as their material model. Their rotation loading and space fixation was performed in the BOUNDARY_PRESCRIBED_MOTION_RIGID control card.

The shown screenshots demonstrate different stages of profile formation: from the first crossing, where the initial stripe capture is performed, to the final (calibrating) crossing, after which the ready product is formed.

Animation of shaping process (higher rolls are shown semitransparent for better visualization) you can see here: