Optimized Design of Cold Roll Forming Process for Production of Rectangular Pipe Based on the Taguchi and Finite Element Method

This paper focuses on the optimization design for reshaping of circular pipe into a rectangular pipe based on the Taguchi and finite element method. In this work, tube reshape into a rectangular section between four pairs of contoured rolls. The roll is assumed to be rigid and for the deformable steel pipe, an elastic-plastic analysis with shell element, throughout 3D sequential and incremental lagrangian analyses, is carried out. The influence of different process parameters such as round mother tube size, tube thickness and different design methods of roll is investigated on the quality of product by using the validate Finite Element method and set of experiment. Quantities such as sides' flatness and outer corner radius of the rectangular tube were observed and measured. The optimization process is performed to achieve the flatness of side and minimize the outer corner radius as the objective function to assure the high forming accuracy. Results obtained from this paper provide valuable guidelines for better understanding of the deformation characteristics and precise control of this process.

Keywords:

Roll forming , , Reshaping of pipe , Taguchi method , FEM ,