Development of an Algorithm for the accelerated Simulation of Roll Forming Processes

连续成形工艺设计的解析算法通常假设平稳性。这对于辊轧成形尤其如此。在工艺设计过程中，不稳定区域（即在型材进入轧机机架或从轧机机架离开时）的影响仍未得到考虑。相比之下，基于有限元方法的模拟为这些区域提供了准确的结果。到目前为止，它们的主要缺点是不能利用源于平稳性的过程中的相似性。因此，辊弯成形过程模拟的计算时间取决于型材设计，从几天到几周不等。本项目的方法是将计算出的过程状态变量外推到下一个成形步骤，一旦它们变得稳定。 在这样做的过程中，没有显着变化的状态变量的过程中的平稳期可以跳过，从而加快了simulation.Using简单的配置文件作为测试用例的头两年的项目服务，以确定合适的标准，确定平稳性和识别参数的影响范围和工件的非平稳区域的特性。这些结果导致了一种自动算法的开发，该算法以一种计算时间减少约10%的方式增强了FE模拟。百分之五十相应的结果是可比的定期FE模拟和实验验证。该项目的第三年的目标是开发的算法应用到更复杂的配置文件。由德国型材制造商制造的实际型材作为测试案例，用于评估新方法在工业应用中的通用性和实际可用性。

Analytical algorithms for the design of continuous forming processes usually assume stationarity. This is especially true for roll forming. The impact of instationary regions (i.e. at the entrance or exit of profiles to the rolling stand) remains unconsidered during process design. In contrast, simulations based on the finite element method provide accurate results for these regions. Up to now, their main disadvantage is a disability to exploit similarities within the process originating from stationarity. Hence, computation time for the simulation of roll forming processes ranges depending on the profile design from several days to several weeks.The approach of this project is to extrapolate the calculated state variables of a process to the next forming step as soon as they become stationary. In doing so, stationary periods of the process with no significant changes of state variables can be skipped and thus the simulation is accelerated.Using simple profiles as test cases the first two years of the project served to determine suitable criteria for the determination of stationarity and to identify parameters with influence on the extend and characteristics of instationary regions of the workpiece. These results led to the development of an automated algorithm, which enhances the FE-simulation in a way that computation time was reduced by approx. 50%. The corresponding results were comparable to those of regular FE-simulations and validated by experiments.The third year of the project aims for an application of the developed algorithm to more complex profiles. An actual profile manufactured by a German profile manufacturer serves as a test case for an evaluation of the generalizability and practical usability of the new method for industrial application.