Numerical simulation of multiple-step incremental roll-bending forming of large-scale sheet metal with U shape

Simulation of multiple-step incremental roll-bending forming and spring back of large-scale sheet metal with U shape was implemented in this paper using ABAQUS,in which the low-carbon steel is selected as the material type.In view of the semi-ellipse shape of workpiece,a geometric plan using fives arcs with different radius to approach the original shape in piecewise is proposed.On the basis of the programming and according to the possible defects in the processing,the rolling steps are reasonably arranged,and the parameters are adjusted in ABAQUS.The largest error of curvature radius of different arcs is less than 5% after simulation of the sheet metal forming according to optimized process fitting with origin8.The results show that the incremental roll-bending method for forming the semi-ellipse shape workpiece is feasible and the simulation process meets the requirements of the quasi-static response.