Roll-formed sections are widely used in various areas of production and construction. Most roll-formed sections used in construction have a protective and decorative coating to prevent corrosion. As a rule, sheet material with coating applied is used in the process of roll-formed sections production. It allows to increase the economic feasibility of production and improve the quality of sections, but at the same time coating can be damaged during sections manufacturing.

One of the main reasons for coating damaging is excessive allowable contact pressures applied on the surface of the coated sheet, so studying of contact effects in the process of roll-formed sections manufacturing is an important and urgent task.

Drilling is one of the main processes of materials machining by cutting. Drilling makes it possible to obtain holes of various sizes in a wide variety of metals, alloys, non-metallic materials, composites, etc.

Defects can occur during drilling, e.g. hole deviation from roundness, burrs, delamination, etc.

LS-DYNA allows to study the machining process in detail and identify what causes formation of defects.

Crash test simulation is an integral part of car passive safety testing. It is used by many companies engaged in car design.

Simulation of car crash tests with various types of road fences allows to estimate their impact resistance and energy absorption capacity. In most cases LS-DYNA is used to simulate crash tests.

For the purposes of assessment of required parameters related to road fences and cars, LS-DYNA was used to create finite element models of cars and road fences. A structure consisting of several profiles. And two types of posts were used: channel-type and C-type. Cars were driven at a speed of 24 to 80 km/h and crashed against the road fence.

Today profiles made from round billets of various diameters using rollers of profile bending machines by reduction or drafting are widely used in machine-building and construction.

Due to the fact that most pipe billets are welded, i.e. there is a welded seam, which causes formation of waviness along the axis of the billet, it is necessary to use a correct straightening and levelling unit, which allows to eliminate this defect.

LS-DYNA was used to construct a finite element model of a correct straightening and levelling unit consisting of correct rollers arranged in staggered order at certain distances from each other. LS-DYNA was also used to simulate operation of this unit.

PC Ulyanovsk NIAT has applied engineering analysis for more than 10 years for development of new process and flow diagrams for both research and applied tasks. During this period, an extensive experience of engineering analysis application has been accumulated both in the scope of metal working process and in other spheres.

The LS-DYNA license program is used as the main program for engineering analysis at PC Ulyanovsk NIAT. The program is used for analyzing various dynamic processes being one of the best for metalworking processes simulation.

The process of profiles manufacturing in rollers is one of the most progressive processes in sheet metal treatment under pressure. The profiling speed can be 150 m/min or higher. At the same time the process has its drawbacks, in particular, in case of intensive patterns of shaping or non-optimal angles of profile elements bending, plastic deformation of the profile edges that cannot be eliminated can occur, which contributes to the formation of longitudinal profile bending or edge waviness along profile legs under the action of residual stresses.

The main task when designing a tool for roll-formed shapes cutting is to select the optimal configuration of the cutting knife, which shape should provide high-quality profile cutting, no defects in pre-end zones and the minimum cutting force. The main factor that can ensure these conditions is the angle of profile cutting.

To evaluate the impact of the cutting angle on the energy and force parameters of the process, the guillotining model was investigated, where the impact of angle ‘a’ on the force and energy of cutting was determined. The study was conducted in the program LS-DYNA.

Use of corrugated steel pipes is a modern method applied in the construction of passages and bridges of railroads and highways. It is characterized by minimal expenditures for materials, low cost of pipes installation in structures, reduction of construction time and insignificant costs associated with pipes transportation to the assembly and installation site.

Ulyanovsk Research Institute of Aviation Technology and Production Organization has been developing this technology.

Computer simulation allows replacing a real design, technological or physical process by a virtual one. When is it necessary? Almost always when we develop something new.

Stages of preparation and computational analysis

An engineer develops a new technological process or a designer designs a new part, for example, a motor hood. How to check what will happen to this hood, for example, on impact with another car or an obstacle. Earlier it was manufactured, then installed on a real car and after that it was required to run this car into another one or a wall. All of that resulted in high financial costs. And imagine that you need to work at, let's say, 100 design options of the hood. How much money will you have to invest in it? A vast amount of money! What should we do? The answer is to use computer simulation and transfer the entire process to a computer. I mean to perform these 100 collisions or crash tests using a virtual car but not a real one.

The current work lightens the outcomes of simulation of cutting process for locked design by punches of different shape. The optimum shape of a punch ensuring minimum contortion of profile’s cross section is selected. The mathematical simulation is performed by the agency of the LS-DYNA, v. 971 software. The research was conducted by Joint Stock Company “Ulyanovsk NIAT”.

The article is dedicated to the process of metal separation of between a punch-cut and die body for the locked designs. The given process is peculiar for the use of a cropping die, which usually is not applied for the locked designs due to their cross section contortion.

Full article - Simulation of cutting shape process for different forms of punches

This work presents the results of simulated process of manufacturing V-figurative type section from blank with round holes. The reasons of distortion of round holes and transformation of holes to shape of an ellipse are described. The features of forming of section depending from holes are revealed. The mathemati-cal simulation is executed in the program LS-DYNA of version 971. This work presents the results of simulated process of manufacturing V-figurative type section from blank with round holes. The reasons of distortion of round holes and transformation of holes to shape of an ellipse are described. The features of forming of section depending from holes are revealed. The mathemati-cal simulation is executed in the program LS-DYNA of version 971. 

In present paper the process of manufacturing of V-figurative section from blank with round holes is described. The holes of the round shape have diameter of 10 mm. There is a distortion of the shape of holes during forming blank in roller caliber.

Full article - Simulation the process of manufacturing v-figurative type section from blank with holes