Optimization of Strain Distribution in the Roll Forming Process Using the Desirability Function and Finite Element Methods

Defects of the roll forming process are affected by the amount and situation of the strains distribution. The effect of the process parameters on the strain distribution in the round cross section roll forming process has been studied. Finite element and response surface method have been used for process modelling. Then, desirability functions approach and overlaid counter plots were employed for optimization of the process. Three factors including the roll diameter, distance between the stations and linear speed of the sheet were considered as the input parameters. The sum of longitudinal maximum strain and transverse strain distribution uniformity were taken as response functions. Response function model for each function was obtained using the RSM. Finally, optimization of the process was done using the desirability function approach and overlaid contour plots. The results show that both of the response surface models have good model adequacy. Optimization by desirability functions approach was presented as points which according to the type of the process and production requirements can only be used to start and preliminary design. But the overlaid contour plots have flexibility in output for manufacturing processes. Output overlaid contour plots provide optimum area that there is wide range of values for choices in different condition.