Optimization of roll forming process for different standard sections of steel structures

In this research paper the three-roll bending forming optimization for different sections of steel structure was studied. The three-roll forming method is suitable for forming a circular and curved type of work-piece. An analytical model and finite element model (FEM) using ANSYS are proposed for investigating the roll forming process for various sections of steel. The deformation analysis is presented for different sections such as right angle, solid circular, hollow circular, T, I, Z sections. A reasonably accurate relationship between workspace displacement and the desired thickness of various sections of steel structure is focused. The bending force is optimized by using the Lagrange method. The minimum bending forces with respect to thickness for different sections of steel was examined. A circular shaped work piece with radius 609.6 mm section dimension 25 mm x 25 mm x 3 mm is simulated with FEM established by the optimum tool and process parameters. The optimum bending force is obtained from SCILAB code. The SCILAB CODE has been developed for optimization purposes in the proposed study. The optimization model is validated with the available literature. A good agreement is found between available literature and present analysis. It is also found that the relation between minimum bending forces with respect to thickness for different sections is parabolic in nature. The present work is expected to provide generalized guidelines for design and manufacturing engineers to lay a process plan for developing different standard sections of steel using roll forming process.