Computational Simulation of Cross Roll Straightening

Abstract eng:
The paper deals with numerical analysis of the process of cross roll straightening of circular bars in a seven-roll straightening machine. In this machine, initially curved bar rotates along its axis as it progresses through laterally staggered rolls, being loaded by a fluctuating bending moment beyond its elastic limit. To simulate the process efficiently, special program was developed, based on a beam-type finite element, Euler scheme of material flow along the straightened bar and nonlinear iterative solution of the elasto plastic material behavior. Based on the input data, process characteristics like roller loading, product deflection, curvature and plasticization can be quickly obtained. With reliable solution of the direct problem, optimal intermeshing of rollers for given input data can be found in an iterative process. The paper describes main features of the algorithm and examples of its application.

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