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Picture 8 shows changes of the workpiece thickness during the forming process. Picture shows that value of the greatest thinning is about 3%. Taking into account the value of the workpiece thickness is equal to .0236” (24 Gauge or 0.6mm), the absolute value of the thinning is 0.000708”.Pic. 8. Changing of the workpiece thickness in process of forming according to the Regular Rollforming MethodNow we’ll do same research for the Intensive Deformation Rollforming method. Same thickness, material, profile and desire to get it well done in 7 passes. Picture 9 shows rollforming result of rollforming with intensive deformation rollforming method and there is no edge deformation, ripples or waves seen. And next two pictures show why it works.
а – overall view b – right side edge c – isometric viewPic. 9. Workpiece in process of rollforming by method of intensive deformation.Picture 10 shows the values of equivalent stresses, the highest value is 353 MPa, which is slightly higher than the elastic limit (350 MPa), and as a result tensile plastic deformation forces in the edges will be small and most probability we won’t see any rollforming defect on the profile edges.Pic. 10. Equivalent stresses in a workpiece in process of rollforming by the method of intensive deformationPicture 11 shows the values of tensile stresses, the highest values reach 367 MPa, which is ~10MPa lower than the traditional method rollforming.Pic. 11. Longitudinal stresses in a workpiece in process of rollforming by the method of intensive deformationPictures 12 and 13 show how the value of the tensile stress of a metal particle located on the left and right edges of the workpiece changes, respectively, when the workpiece moves through the roll-forming stands. Red color shows stress for rollforming by RR, and blue for IDR. Vertical dot-dash lines indicate the position of the axial planes.Pic. 12. Stretching stresses in the left edge of the workpiecePic. 13. Stretching stresses in the right edge of the workpieceThe values of longitudinal deformations in a workpiece during rollforming by the method of intensive deformation shown in Pic. 14. The greatest values of deformations are about 0.7%, which is about (2%) less than with rollforming up to traditional method.Pic. 14. Longitudinal deformations in a workpiece in process of rollforming by the method of intensive deformationThe highest change of the workpiece thickness during rollforming according to the IDR (Pic. 15) is 1.4%, which, in terms of the absolute value, is 0.00033”Pic. 15. Change of the thickness of the material in process of rollforming by the method of intensive deformation
These simple mathematical modeling shown that it’s possible to fit good quality rollforming design in up to 30% less passes using only one method. Same time combining several methods it can be up to 40%.