Optimization of roll forming process for high-strength V channel steels

Due to the complicated deformation of the billet in roll forming process and the lack of the theoretical understanding, there are still no unified methods to design and optimize roll profiles. Theoretical analysis of the deformation in roll forming process based on mathematical method is efficient and necessary. A qualified roll profile optimization method should be based on the accurate calculation of the spatial configuration of the billet. However, the existing models for calculating the spatial configuration of the billet in roll forming process cannot calculate the springback of the billet. In this paper, according to the mathematical model established by the author for calculating the spatial configuration of the billet, a roll profile optimization method for high-strength V channel roll forming process was proposed by taking the maximum edge membrane longitudinal strain as constraint conditions. After optimization, the number of roll stands required for final V channels was reduced from 8 to 5. Through analyzing and comparing the deformation of the billet in simulation results of bending and roll forming process, it is found that bending tests can also be used to verify the feasibility of the roll profile optimization method proposed in this paper. The bending tests were carried out using the original and optimized process parameters, respectively. The results show that the shape of the V channel obtained by the optimized process parameters is much closer to that of the designed V channel.