BySrinivas Reddy
Hadley Industries生产冷轧成型产品，主要用于建筑和建筑行业。该公司开发和获得了一种称为Ultreseel的冷成型过程，通过在卷成形操作之前通过赋予凹陷图案来显着提高带钢的机械和结构性。
Ultraseel在冷轧成型过程之前使用具有特殊齿的一对带有特殊牙齿的牙齿，该牙齿从普通纸张的两侧形成凹坑形状。凹陷钢产品越来越多地用于各种应用，包括墙壁螺柱，框架和屋顶构件，波纹板，葡萄园柱，门增强和许多其他应用。
Before committing to dimpled steel products, customers need to investigate their performance by estimating section properties such as stiffness and load-carrying capacity in order to make a buying decision. However, finding a means for estimating dimpled steel’s properties proved elusive when Hadley first developed it because of the differences between UltraSTEEL and standard cold-roll formed products.
冷轧产品形成一个统一的标准cross-sectional geometry, so theoretical calculations can be relatively easily performed to determine their section properties. The UltraSTEEL process, however, creates more complicated material properties that vary over the geometry. Interrelated nonlinear changes in contact, geometry and material properties occur during production and subsequent section forming and secondary operations. Simplified theoretical calculations cannot accurately analyze the performance of such a complex material.
While physical testing is a possible solution, it is prohibitively expensive with tooling costs running anywhere from $30,000 to $150,000 per part being a major obstacle to dimpled steel’s adoption.
Digital simulations replace costly physical testing
基于过去的仿真经验，哈德利开始使用非线性有限元分析（FEA）软件来预测超级型工艺，冷轧成型和二次过程发生的几何形状和材料特性的变化。
The challenge is accurately simulating the dimpled steel production processes and applications under loading. Accurate prediction of the final product behavior requires simulations that connect to previous or subsequent simulations while taking into account the changes in geometry, material and structural properties of the materials.
Hadley is able to simulate the UltraSTEEL process from start to finish in MSC Software’s Marc non-linear analysis solution, with the following steps:
1) the dimpling process that deforms a flat steel strip into a dimpled strip
2）冷轧成形过程，产生所需部分，和
3）额外的过程，如剪切切割和虚拟测试的张力，弯曲，压缩负载等产品。
The geometry and material data of the dimpled strip is transferred from one process to the next in a closed loop. This approach is practical for small sections of dimpled products and optimizing the dimpling process itself.
对于大量元素的较大模型，Hadley Group使用简化的方法来计算凹陷产品的性质。工程师通过生产单个凹坑来模拟扁钢板的变形。该一般凹坑几何形状用于产生凹陷的条带;3D元素用于较小的产品，壳体元件用于较大的产品。
Only the geometry of the dimple is transferred from the dimpling process. The material properties of the dimple are provided from a separate tensile test on a dimpled steel sample. This test can be quickly and inexpensively performed without tooling. The next step is simulating the cold-roll forming process that shapes the dimpled strip into the desired product, other processes and applications.
In an example of the simulation process, a CAD model of the top and bottom rolls was imported into the Marc software. These rolls were modeled as rigid bodies that rotated around their central axes.
普通条带在Marc中产生，并置于两辊之间的预定位置。弹性塑料材料模型用于205 GPa的杨氏模量，泊松比为0.30。通过条带厚度使用五层元件以模拟弯曲和拉伸现象。评估两种不同的网格，一个具有37,980个固体元素，另一个具有149,810个固体元素。凹点模拟表明，两种网格中发育的最大塑性应变和应力分别在小于7％和4％，因此较粗糙的网格用于研究的平衡。
The top and bottom rolls had an overlapping gap of 0.40 mm between the mating teeth. The sheet was fully fixed at one end and initially fed to the rotating rolls with a velocity equal to the linear velocity at the tip of the roll teeth. When the roll teeth just grasped the strip, the fixed end was released and the strip was deformed by the rotating rolls.
The original plain sheet and the dimpled sheet were used in tension and bending simulations. The engineering stress and strain data of the plain steel sheet were obtained from tensile tests. The dimpled sheet was merged into the new model in order to start the new analysis and the pre-state option was employed to directly transfer result data from the previous dimpling process into the tensile and bending simulations.
Simulation results confirm UltraSTEEL’s technical superiority
Both simulation approaches have been validated by experimental results comparing the 3D geometry of the predicted shape with scanned data of the physical sample. The geometry of the predicted dimpled sheet differed from the actual process by less than 1.7 percent.
仿真结果的细节来自生产线的凹陷金属。
Accurate simulations have enabled Hadley to substantiate technical superiority about dimpled steel produced through the UltraSTEEL process. With the simulations providing customers with the data they need to make buying decisions, Hadley has forecast an eventual sales volume of more than $4 million for dimpled steel products. It has also generated additional revenue by licensing the process to other manufacturers.
生物：Srinivas Reddy是MSC Software Inc.的高级产品营销经理，目前负责FEA产品线。在加入MSC之前，他担任印度海滨航空公司有限公司的工程师，并作为咨询工程师，帮助工程师，汽车，石油和天然气和生物医学行业的工程师分析了仿真软件的产品。在MSC软件上，他曾举办过几个角色，包括技术顾问，应用工程师和产品经理。Reddy在印度理工学院，钦奈，印度，宾夕法尼亚州立大学的工程科学和力学博士学位拥有BS学位。
MSC Software Corp.
www.mscsoftware.com.
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