Equivalent load model for the numerical simulation of integrated induction heating and mechanical rolling forming of curved hull plates

Integrated induction heating and mechanical rolling forming (IH-MRF) is a new method for producing complex curvature hull plates. The plate undergoes deformation through sequential or simultaneous action of induction heating and mechanical rolling. Understanding the mechanism of this forming process is essential for developing intelligent forming systems. Finite element simulation is a leading research tool in this area. However, the rigorous requirements on the number of model nodes and incremental steps of the simulation for direct modeling of inductor and rollers result in inefficient modeling and calculation processes. To address this issue, an equivalent load model for IH-MRF simulation is proposed in this study. The inductor is simplified to an equivalent heat source model, and the roller is simplified to an equivalent mechanical load model. The equivalent load model for the simultaneous action of induction heating and mechanical rolling is a simple superposition of the equivalent heat source model and the equivalent mechanical load model. The experiment and simulation results are consistent in terms of temperature trends, temperature values, and deformation. The research in this paper lays the foundation for developing an intelligent IH-MRF forming system based on finite element simulation methods.