Study of board-fins forming process

Variety of board-fins are widely used in the industrial field, however, many problems such as technical complexity, fins falling, high rate of rejection, high cost and so on exist in the manufacturing methods available. In this paper, aiming at the problems existed in present methods, a new rolling technology used to shape board-fins was developed based on the traditional rolling principle. The forming process, forming principle and key techniques were studied. Based on the analysis of plasticity roll forming principle and relative motion between rolling tool and workpiece, the structure and dimensions of the rolling tools were designed according to the specifications of the fin shape. The finite element models of rolling tool and the workpiece were established. The forming process was simulated with Deform-3D, the three-dimensional dynamitic simulation of the board-fins rolling process was realized. Experiments were carried on the refitted experiment equipment. The experimental results were consistent with simulation results, which verified the validity of the proposed board-fins rolling method and effectiveness of the simulation model.