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The purpose of simulation application lies in improving process technology methods, enhancing product quality, mastering the process of cold roll forming, reducing roll repair and design modification, and saving production and debugging costs. Cold roll forming process simulation cannot be separated from the experience of roll designers and the installation and debugging process of forming equipment. Simulation without the experience and process knowledge of cold roll forming is meaningless and can lead to serious consequences in practical applications. Designers must undergo training to become experts in finite element simulation technology, and simulation software must adopt the professional terminology of cold roll forming designers. The development cycle of rolls can sometimes last for several months, but generally only a few weeks. Therefore, a set of roll designs can only be used for one to two weeks at most, including the time for roll processing (turning, grinding, quenching). Even with advanced software and high-speed personal computers, finite element simulation of the cold roll forming process can take several hours or even days. The simulation calculation time can be minimized by the following methods: pre-optimizing the roll set with a simulation analysis model; optimizing the roll set with finite element analysis. The best method is to analyze with a professional software package for the cold roll forming industry.

The first step in roll optimization is geometric simulation. Factors that must be considered for the geometric characteristics of the system include: forming curve, roll diameter, plate thickness, cross-sectional shape, roll type, and some material properties. The main goal of simulation is to determine the minimum number of passes for forming according to the requirements of the user's product, and to smoothly distribute the forming work among these passes. The simulation can complete the calculation of each optimization variable in just a few seconds, helping roll designers quickly determine the optimal number of passes and forming process sequence from their initial ideas. The main idea of simulation is that the surface shape of the deformation zone between adjacent passes can be described by a specific deformation curve. The deformation curve is a sectional curve of the edge of a forming cross-section before entering the next pass. It can be imagined that describing the deformation curve with a straight line is too simplified and does not match the actual situation. In the past, a large number of studies used sine curves and polynomial functions to describe the shape of the deformation zone, conducted a large number of experiments and finite element simulations, making these research results more consistent with actual engineering. Nowadays, software can analyze the stress occurring in the forming direction and cross-section based on the deformation length

In order to verify the optimized roll design, finite element simulation must be conducted. As an important component of quality management, the simulation aims to verify and check the roll design, seeking solutions to specific problems in cold bending technology. Finite element simulation has been applied in the following aspects of cold bending forming: Welded pipe industry: applicable to rolls with multiple specifications of plate thickness, side roller forming, release angle, edge wave of plate strip after opening the pass, welding quality, roll wear (caused by excessive local contact pressure), free deformation, sizing quality, welding compensation, etc. Profiled plate section: bag wave, thinning in the bending area, arching of straight components, edge wave of plate strip, non-ideal metal flow, etc. Open and closed sections: including all the above contents for welded pipe forming and profiled plate section, as well as some unique issues such as pre-punching deformation, material hardness, bending rebound, contour dimensions such as height/width/thickness ratio.

The results and information from finite element simulations can be used to verify roll design and facilitate further optimization. In most cases, cold roll forming enterprises do not have their own research institutes capable of conducting professional verifications. Even if they do, due to the language barriers between finite element analysts and cold roll forming designers, effective collaboration on research is challenging. Therefore, using improved finite element simulation software tailored for cold roll forming is a good choice. Such software can automatically establish a finite element simulation model, generate sufficient elements, set reasonable boundary conditions, and optimize simulation settings

Additionally, finite element simulation software can express results more clearly using professional terminology specific to cold roll forming. Users can operate virtual cold roll forming machines. Tests that were often conducted in practice can now be done using simulation software, overcoming the limitations of having to practice on production lines and certain forming passes. It should be noted that simulation software can be used during the roll design stage. This can save costs such as the production cost of useless rolls, rework costs for defective rolls, installation and debugging time, downtime for repairs, and increase technical know-how and experience for future project development.

Industrial applications have confirmed the necessity of quality management: scanning the geometric profiles of rolls used in production and after a production cycle. Using the geometric data of actual rolls for finite element simulation can provide cold bending engineers with practical information about the cold bending production line. Roll wear and critical states can be detected through maintenance. The stable use of rolls not only reduces production costs but, more importantly, comprehensively improves product quality. The first step of rapid optimization design is carried out using geometry simulation software. After roll design, further one or two rounds of finite element simulation analysis are used to verify the design results. The concept of industrial application value is reflected in reducing design costs, decreasing debugging expenses, and improving the enterprise's cold bending technology level.