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Cad Systems for Roll-Forming Equipment and Tools: Development Outlook

Article  in  Metallurgist · April 2017

DOI: 10.1007/s11015-017-0417-9

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DOI 10.1007/s11015-017-0417-9
Metallurgist, Vol. 60, Nos. 11–12, March, 2017 (Russian Original Nos. 11–12, Nov.–Dec., 2016)

CAD SYSTEMS FOR ROLL-FORMING EQUIPMENT

AND TOOLS: DEVELOPMENT OUTLOOK

V. A. Osadchii, S. M. Gorbatyuk, UDC 621.771.22

D. I. Filippov, and N. S. Kuprienko

Prospects of roll-forming are analyzed. Requirements to the computer-aided design (CAD) of roll-forming
equipment and tools are formulated. The CAD system developed by the MISiS is described.
Keywords: rolling, bending, roll, roll-formed section, computer-aided design.

In Russia and the CIS countries, there are many small and medium companies that produce roll-formed sections and
roll-forming equipment. This is due to the demand for roll-formed sections in various fields such as the aircraft and automo-
tive industries, mechanical engineering, and construction [1]. Moreover, the proliferation of small roll-forming companies is
promoted by the relatively low cost and small dimensions of the equipment and very high metal utilization factor and rate of
return of capital investments.
When roll-formed sections are in great demand, an important issue is to develop special software that would facilitate
the designing of roll-forming equipment, such as roll-forming mills. Such software should perform the following functions:
1) computer-assisted entry of input data (material characteristics, geometry of sheet, and the way it is fed to the rolls
(continuous, single-piece, or individual-coil feed) [2]);
2) visualization of the roll pass sequence, with indication of weaknesses (possible folding, possible cracking, impos-
sibility of providing the required bend angle);
3) determination of the bend angles for each pass [3, 4];
4) mathematical simulation of each pass on stands for better control of the roll-forming process;
5) automatic output of appropriate roll-pass drawings;
6) automated design of equipment of a roll-forming mill: entry-end equipment (coil take-up, decoiling, loading to the
leveller, coil end butt-welding, loop storage), roll-forming stand, exit-end equipment (cutting off to length, stacking, packing [5]);
7) automatic selection of equipment to meet the requirements and calculations;
8) rough estimation of the cost and time of equipment manufacturing; and
9) project printout (equipment layout, drawings of equipment and roll passes, tables of calculated process character-
istics and final cost of equipment, mimic diagram of the process).
Such software would allow resolving the issue of producing complex profiles and reducing substantially the equip-
ment design stage. The software developed by the MISiS performs some of the above-mentioned functions, including the
following stages.
Data input. The graphic editor is simple. It allows generating a final profile (Fig. 1). After that, the sheet geometry is
specified (Fig. 2).
The required material is selected from the material library, and its material characteristics are displayed (Fig. 3). In
addition to popular steels, the library includes various alloys.
The required specifications of the equipment are input data as well (Fig. 4).

National University of Science and Technology MISiS, Moscow, Russia; e-mail: vaosadchy@yandex.ru, sgor02@mail.ru. Translated from
Metallurg, No. 11, November, 2016, pp. 28–30. Original article submitted October 6, 2016.

1130 0026-0894/17/1112-1130 ©2017 Springer Science+Business Media New York

 Fig. 1. Graphic editor.

Fig. 2. Sheet geometry. Fig. 3. Material selection.

Fig. 4. Equipment specifications.

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 Fig. 5. Table of bend angles.

Fig. 6. Bending sequence.

Bending sequence. The appropriate design of bending sequence is the major contributor to the success of the
roll-forming process. The bend angles per each of the passes (stands) are summarized in a bend-angle table (Fig. 5).
For better illustration, the bending sequence can be displayed, with the deformed zones being darkened (Fig. 6).

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 Fig. 7. Table of process characteristics.

Fig. 8. Ring data.

Data output. After all necessary data are entered and the bending sequence is designed, the parameters of the process
for each pass are computed automatically. If results are correct for all passes, a table of process characteristics is displayed
(Fig. 7); otherwise, the user has to change certain bend angles until obtaining the correct result.
At the final stage, the user is offered to partition the designed shaped roll shells into ring sections. The user can
choose the partition generated be the program based on the load and convenience (Fig. 8) or do partition the way he sees fit.
There are two output tables: one collects summary data on the rings and the other, detailed data. After the completion
of computations, the user is offered to save the detailed and assembly drawings of rolls as dwg-files.
Conclusions. The main requirements to the CAD of roll-forming equipment and tools that allow creating effective
roll-forming mills in the shortest possible time have been formulated. Expanding upon the studies [6–8], the MISiS has de-
veloped CAD software to design and draw roll passes for producing sections of various shapes, with indication of roll mate-
rials. This software is currently updated to include the options of equipment design and sheet forming simulation.

REFERENCES

1. H. Yang, H. Li, Z. Zhang, et al., “Advances and trends on tube bending forming technologies,” Chinese J. Aeronaut.,
25, No. 1, 1–12 (2012).
2. I. S. Trishevskii, V. I. Miroshnichenko, V. P. Stukalov, et al., Roll Pass Design for Roll-Forming, Tekhnika, Kiev
(1980), pp. 6–9.
3. I. S. Trishevskii, A. B. Yurchenko, V. S. Mar’in, et al., Roll-Forming: Equipment and Technology, Metallurgiya,
Moscow (1982).

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4. A. P. Chekmarev and V. B. Kaluzhskii, Roll-Formed Sections, Metallurgiya, Moscow (1974).
5. A. V. Filimonov and S. V. Filimonov, Production of Half-Closed Roll-Formed Sections by Intensive Deformation,
Izd. UlGTU, Ulyanovsk (2010), pp. 39–43.
6. S. M. Gorbatyuk, V. A. Osadchii, and E. Z. Tuktarov, “Calculation of the geometric parameters of rotary rolling by
using the automated design system Autodesk Inventor,” Metallurgist, 55, No. 7–8, 543–546 (2011).
7. S. M. Gorbatyuk and A. V. Kochanov, “Method and equipment for mechanically strengthening the surface of roll-
ing-mill rolls,” Metallurgist, 56, No. 3–4, 279–283 (2012).
8. S. M. Gorbatyuk and L. V. Sedykh, “Improving the durability of rolling-mill rolls,” Metallurgist, 54, No. 5–6,
299–301 (2010).

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