COLD ROLL FORMING SIMULATION AND ORTHOGONAL EXPERIMENTAL OPTIMIZATION OF SPIRAL CORRUGATED STEEL TUBES

The cold-roll forming process is capable of producing intricate profiles, and optimizing its parameters can enhance the quality of the final product. This study focuses on analyzing the roll forming of spiral corrugated steel tubes made from galvanized sheet BGH340. The professional roll design software COPRA is utilized to design the rolls, and a three-dimensional finite-element analysis model for spiral corrugated steel tubes rolls is established. Orthogonal experiments are conducted to investigate the effects of the friction coefficient, line velocity, and rotation angle on the maximum longitudinal strain. The results indicate that increasing the friction coefficient can help reduce the strain, but may also result in defects such as scratches. Line velocity has the most significant impact on strain, with higher line velocities leading to increased strain and resulting in side wave and plate surface inequality defects. The rotation angle has a minimal influence on strain levels. The optimum contour parameters are deduced based on these findings, providing a theoretical foundation that directly contributes to improving the production efficiency and ensuring higher quality in the manufacturing of spiral corrugated steel tubes.