Numerical Simulation of Profile Forming Process on a Four-Roll Plate Bending Machine
Authors: Ahmed Soliman M.E., Chinakhov D.A., Kurlaev N.V.
Published in issue: #4(172)/2026
Category: Metallurgy and Science of Materials | Chapter: Metal Forming
The process of forming a channel profile from a steel sheet blank on a four-roll plate bending machine has been investigated. The aim of the study is to develop a high-accuracy numerical model of step-by-step forming of a sheet blank, enabling prediction of the three-dimensional stress–strain state, distribution of equivalent stresses and strains, and variations in the geometric parameters of the profile at all stages of forming, as well as to establish a calculation methodology for evaluating material formability and process stability using the forming limit diagram (FLD). To achieve this aim, numerical simulation based on the finite element method, implemented in the LS-DYNA software package, was applied. A three-dimensional mathematical model of the interaction between the blank and the forming rolls was developed, taking into account contact conditions, elastoplastic material behavior, nonlinear properties of steel, and the sequence of technological stages. The model makes it possible to trace the evolution of profile formation, identify zones of local stress concentration, assess the effect of cumulative plastic deformation, and analyze the influence of forming angles, inter-roll distance, and sheet thickness on the distribution of stresses and strains. Within the scope of the present study, experimental validation is not considered; the main focus is placed on the development and analysis of a numerical methodology for predicting the channel profile forming process. To analyze the risk of defect formation and assess the material limit state, an FLD analysis was performed, enabling the identification of safe deformation zones and regions of potential failure without the need for physical experiments. As a result of numerical simulation, detailed fields of equivalent stresses, longitudinal and transverse strains were obtained; changes in the geometric parameters of the profile at each forming stage were calculated, and a comparison of the computed strains with the forming limit curve on the FLD diagram was performed. Analysis of the influence of key process parameters on strain uniformity and the minimization of stress concentrations makes it possible to optimize the sequence of forming passes and the parameters of the roll tooling. The developed numerical model not only enables prediction of the geometry of the finished profile, but also serves as a computational and methodological basis for planning cold roll forming processes.
EDN SVRWXV
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