ﻣﻄﺎﻟﻌﻪ ﻃﻮل ﺗﻐﯿﯿﺮﺷﮑﻞ در ﻓﺮاﯾﻨﺪ ﺷﮑﻞدﻫﯽ ﻏﻠﺘﮑﯽ اﻧﻌﻄﺎفﭘﺬﯾﺮ

Study of Deformation Length in Flexible Roll Forming Process

ﻓﺮاﯾﻨﺪ ﺷﮑﻞدﻫﯽ ﻏﻠﺘﮑﯽ اﻧﻌﻄﺎفﭘﺬﯾﺮ، روﺷﯽ ﻧﻮﯾﻦ ﺑﺮاي ﺗﻮﻟﯿﺪ ﭘﺮوﻓﯿﻞﻫﺎي ﺑﺎ ﺳﻄﺢ ﻣﻘﻄﻊ ﻣﺘﻐﯿﺮ اﺳﺖ. در اﯾﻦ ﻓﺮاﯾﻨﺪ، ﺑﺮاي ﺗﻮﻟﯿﺪ ﭘﺮوﻓﯿﻞﻫﺎي ﺑﺎ ﺳﻄﺢ ﻣﻘﻄﻊ ﻣﺘﻐﯿﺮ، ﻣﻮﻗﻌﯿﺖ ﻏﻠﺘﮏﻫﺎ در ﻫﺮ ﻟﺤﻈﻪ ﮐﻨﺘﺮل و ﻣﺘﻨﺎﺳﺐ ﺑﺎ ﻫﻨﺪﺳﻪ ﭘﺮوﻓﯿﻞ ﺣﺮﮐﺖ داده ﻣﯽﺷﻮﻧﺪ. در اﯾﻦ ﻣﻘﺎﻟﻪ ﺑﺎ اﺳﺘﻔﺎده از ﺷﺒﯿﻪﺳﺎزي اﺟﺰاي ﻣﺤﺪود و آزﻣﺎﯾﺶﻫﺎي ﺗﺠﺮﺑﯽ ﺑﻪ ﺑﺮرﺳﯽ ﻃﻮل ﺗﻐﯿﯿﺮﺷﮑﻞ ﺑﻪ ﻋﻨﻮان ﯾﮑﯽ از ﭘﺎراﻣﺘﺮﻫﺎي ﻣﻬﻢ در ﻓﺮاﯾﻨﺪ ﺷﮑﻞ دﻫﯽ ﻏﻠﺘﮑﯽ اﻧﻌﻄﺎف ﭘﺬﯾﺮ ﭘﺮداﺧﺘﻪ ﻣﯽ ﺷﻮد. ﺑﺪﯾﻦ ﻣﻨﻈﻮر، ﻣﺪل اﺟﺰاي ﻣﺤﺪود ﻓﺮاﯾﻨﺪ در ﻧﺮم اﻓﺰار آﺑﺎﮐﻮس اﯾﺠﺎد ﺷﺪ و ﺳﭙﺲ ﺑﺎ ﻣﻘﺎﯾﺴﻪ ﻧﺘﺎﯾﺞ ﺷﺒﯿﻪ ﺳﺎزي و داده ﻫﺎي ﺗﺠﺮﺑﯽ ﺑﺮاي ﮐﺮﻧﺶ ﻃﻮﻟﯽ در ﺑﺨﺶ ﻫﺎي ﻓﺸﺎري و ﮐﺸﺸﯽ ﭘﺮوﻓﯿﻞ ﮐﺎﻧﺎﻟﯽ ﺑﺎ ﺳﻄﺢ ﻣﻘﻄﻊ ﻣﺘﻐﯿﺮ، ﺻﺤﺖ ﻣﺪل ﻣﻮرد ﺗﺎﺋﯿﺪ ﻗﺮار ﮔﺮﻓﺖ. ﻧﺘﺎﯾﺞ ﻧﺸﺎن داد ﮐﻪ ﻃﻮل ﺗﻐﯿﯿﺮﺷﮑﻞ در ﻓﺮاﯾﻨﺪ ﺷﮑﻞ دﻫﯽ ﻏﻠﺘﮑﯽ اﻧﻌﻄﺎف ﭘﺬﯾﺮ، ﻧﻪ ﺗﻨﻬﺎ در ﺑﺨﺶ ﻫﺎي ﻣﺨﺘﻠﻒ ﭘﺮوﻓﯿﻞ ﻣﺘﻔﺎوت اﺳﺖ، ﺑﻠﮑﻪ در ﻧﻮاﺣﯽ ﻣﺨﺘﻠﻒ ﻫﺮ ﺑﺨﺶ ﻧﯿﺰ ﻣﺘﻔﺎوت اﺳﺖ. ﺑﯿﺸﺘﺮﯾﻦ ﻃﻮل ﺗﻐﯿﯿﺮﺷﮑﻞ در وﺳﻂ ﺑﺨﺶ ﮐﺸﺸﯽ ﭘﺮوﻓﯿﻞ ﺑﺪﺳﺖ آﻣﺪ ﮐﻪ ﻧﺴﺒﺖ ﺑﻪ وﺳﻂ ﺑﺨﺶﻫﺎي ﺑﺎرﯾﮏ و ﻋﺮﯾﺾ 38% و ﻧﺴﺒﺖ ﺑﻪ وﺳﻂ ﺑﺨﺶ ﻓﺸﺎري 48% ﺑﯿﺸﺘﺮ اﺳﺖ؛ ﻫﻤﭽﻨﯿﻦ ﻣﺸﺨﺺ ﺷﺪ ﮐﻪ ﺑﺎ اﻓﺰاﯾﺶ زاوﯾﻪ ﺷﮑﻞدﻫﯽ و ﻃﻮل ﺑﺎل ﭘﺮوﻓﯿﻞ، ﻃﻮل ﺗﻐﯿﯿﺮﺷﮑﻞ در ﻫﻤﻪ ﺑﺨﺶ ﻫﺎي ﭘﺮوﻓﯿﻞ ﺑﺎ ﺳﻄﺢ ﻣﻘﻄﻊ ﻣﺘﻐﯿﺮ اﻓﺰاﯾﺶ ﻣﯽﯾﺎﺑﺪ.

Flexible roll forming process is a novel method for producing profiles with variable cross-section. In this process, the position of the rolls is controlled at any time and moved in accordance with the profile geometry to produce the profiles with variable cross-section. In the paper, the deformation length is investigated as one of the important parameters in the flexible roll forming using finite element simulations and experimental tests. For this purpose, a finite element model was created in Abaqus software, and then the accuracy of the model was confirmed by comparing the simulation results and experimental data for longitudinal strain in the compression and stretching zones of a channel profile with variable cross-section. The results showed that the deformation length in the flexible roll forming is changed not only in the different zones of the profile, but also in different areas of each zone. The highest deformation length was obtained at the middle of the stretching zone, which is 38% longer than that at the middle of the narrow and wide zones and 48% longer than that at the middle of the compression zone. It was also found that the deformation length increases in all the zones with the increase of the forming angle and flange length.