Numerical simulation and parameters analysis for roll forming of martensitic steel MS980

Circle-to-square roll forming process of martensitic steel MS980 was studied. A 3D elastic-plastic roll forming finite element model was established with ABAQUS and the influence of material and process parameters was investigated. Four material with different strengths include MS980, Fe360D, DP590, MS1500 were compared to study the effect of material strength. The result shows that as the material strength increase, the fillet radius of formed square tube decrease, corner thickness increase significantly, and the edge convexity is worse. Rolled compression amount distribution is an important parameter in roll forming process. Three distribution schemes were proposed, which were parabola distribution, decline distribution and equal distribution. The result shows that the equal distribution scheme can get good square shape and uniform force on each pass. (C) 2014 Published by Elsevier Ltd.