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.

Determination of contact pressures by theoretical and experimental methods is an extremely difficult task, therefore finite element simulation program LS-DYNA was used for these purposes at Ulyanovsk Research Institute of Aviation Technology and Production Organization.

A roll-formed section 60xBxS was used for studying. Research that presupposes variation of the flange height (B) and the initial thickness of a billet (S) was carried out. 

 Roller accessories with vertical shoulders were used as a tool. It is usually applied for intensive deformation methods. The section was made in four manufacturing steps and had the following angles of bending: 1 - 20, 2 - 45, 3 - 75, 4 - 90 degrees.

INTFOR parameter was used to display contact parameters in LS-DYNA. There are typical areas of contact between the tool and the billet below. The results were displayed using the Interface Pressure parameter, which allows to visualize the contact process.

The results obtained during simulation in LS-DYNA are very close to the experimental results obtained, for example, by the method of paint application. But, unlike the experimental results, simulation also showed the distribution of values ​​along the contact area.

For the purposes of billet simulation it is possible to enter a coating with the required physical properties in LS-DYNA, for example, metal or rubber. It will immediately show areas in which the coating is damaged.