A Study on the Roll Forming Characteristics of an Asymmetric Roller with a 6 mm Steel Plate using the Finite Element Method

摘要

As a novel method to produce a steel beam with 6mm thickness for buildings, a continuous roll forming process is reported. The roll shape is asymmetric and consists of 6 pairs of rollers to bend the steel plate from 0 deg to 90 deg. Results obtained upon application of the roll forming process showed that the angle of the section plate is 90 deg. However, defects such as bowing and camber as high as 3.2 [deg /m] were observed. A FEM (Finite Element Method) analysis was applied to investigate the causes of the results for the region between rollers no. 5 and no. 6. The results of a FEM simulation of deformation and stress showed that there are some strong peak stresses on the upper surface and bottom surface of the material. The positions of the peak stresses did not show a correspondence between the upper and bottom surfaces. Thus, the defects in the process of roll forming with a 6 mm thick steel plate occur by the unbalanced stresses between the upper surface and bottom surface of the material in this study.