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.


Two profiling schemes for a 100x40x2 channel on the initial version (1 version) and on the proposed one (2 version) were simulated. LS-Dyna was used for simulation.

Angles of bending along transitions for the first version are: 15-36-51-62-72-82-92-90, for the second version 11-22-33-45-58-71-82-92.

Longitudinal deformations for the second version are 2-2.5 times lower as compared to the initial (first) version. The distribution of efforts along transitions for the proposed (second) version is more uniform as compared to the initial one. The internal and total energy for the proposed version is 15-30% less as compared to the initial version. After the research conducted by Ulyanovsk Research Institute of Aviation Technology and Production Organization the initial version of forming is no longer applied for these profiles.