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Finite element analysis of circle-to-rectangle roll forming of thick-walled rectangular tubes with small rounded corners

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Abstract

A novel circle-to-rectangle roll forming finite element model of thick-walled rectangular tubes was proposed in this paper. Circle-to-rectangle roll forming is usually used to manufacture thick-walled rectangular tubes. For thick-walled rectangular tubes with small rounded corners (the ratio of outer rounded corner radius to thickness less than 1.5), due to the limitation of measurements of rounded corner stresses, finite element model of the manufacturing process are alternative approaches for predictions of both von Mises stress and equivalent plastic strain in circle-to-rectangle roll forming. In this paper, the finite element model was built based on elastic–plastic finite element method. The simulation results of roll forming were compared with the experimental results to verify the accuracy of the finite element model. Von Mises stress and equivalent plastic strain at the rounded corners were analyzed, the possible crack position of thick-walled rectangular tubes during circle-to-rectangle process was predicted. In addition, the influence of three forming parameters (feeding speed, friction factor, rolling space) for the rounded corners were discussed by the equivalent plastic strain of the inner and outer surfaces. The finite element model of circle-to-rectangle roll forming could provide manufacture guide while manufacturing the rectangular tubes with small rounded corner.

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Data availability

The datasets used or analysed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

This research was supported by the National Natural Science Foundation of China (Grant Nos. 52075492, 11972323, 52205134), the Zhejiang Provincial Natural Science Foundation of China (Grant Nos. LR20A020002, LQ21A020003, LD22E050009, LQ22E050013, 2022C01096).

Funding

This research was supported by the National Natural Science Foundation of China (Grant Nos. 52075492, 11972323, 52205134), the Zhejiang Provincial Natural Science Foundation of China (Grant Nos. LR20A020002, LQ21A020003, LD22E050009, LQ22E050013, 2022C01096).

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Authors and Affiliations

  1. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310014, China

    Zhongyi Luo, Min Sun, Zheng Zhang, Congda Lu & Guang Zhang

  2. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou, 310014, China

    Min Sun, Zheng Zhang, Congda Lu & Guang Zhang

  3. Ganyeah Group Company, Qingtian, 323903, China

    Min Sun & Xiaoyan Fan

Authors
  1. Zhongyi Luo
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  2. Min Sun
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  3. Zheng Zhang
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  4. Congda Lu
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  5. Guang Zhang
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  6. Xiaoyan Fan
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Contributions

All authors contributed to the study conception and design. Investigation, numerical simulations, data analysis, first draft of the manuscript were performed by Zhongyi Luo. Reviewing and editing of the manuscript were performed by Zhongyi Luo, Min Sun and Zheng Zhang. Project administration and supervision were performed by Zheng Zhang, Congda Lu and Guang Zhang. Specimens were tested by Xiaoyan Fan.

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Correspondence to Zheng Zhang.

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Luo, Z., Sun, M., Zhang, Z. et al. Finite element analysis of circle-to-rectangle roll forming of thick-walled rectangular tubes with small rounded corners. Int J Mater Form 15, 73 (2022). https://doi.org/10.1007/s12289-022-01719-y

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