Inverse Engineering and Preliminary Simulation of a Closed Profile Roll-forming Line

Roll-forming is a key technology among Metalsa ́s manufacturing capabilities. The Company’s technology group is conducting research oriented to support future engineering changes and the development of new technology variants. The initial objective of the project is the development of a reliable simulation of one complete roll-forming line using LS-DYNA®. The roll-forming tools were digitized using an optical scanner, converted to 3D parts and finally assembled into the complete forming line. This geometry served as base to generate a finite element model, which was entirely set-up using LS-PrePost®. As a first trial, the elasto-plastic behavior of the sheet strip was modeled utilizing generic material properties. In order to validate the analysis procedure, the production line was halted to allow geometry measurement of cross sections at different forming stations. This article describes the whole procedure utilized along with the comparison of the numeric and physical profiles obtained from the forming process. The numerical model yielded an accurate prediction of the deformed profile. This methodology is used on all virtual validation of new designs before commissioning equipment modification or purchasing.