Analysis of Die-Sheet Contact in the Rolling Process

Sheet metal forming is one of the most usual technologies for obtaining finished products practically in each field of industrial production. In this paper, the study was focused on a sheet metal forming process used in hinges manufacturing called the rolling process. In order to understand the contact mechanism in this process, experimental and numerical studies have been completed. At first, an experimental apparatus was designed and realized to reproduce the real industrial solicitation in the rolling process. After running experimental tests, the load-displacement curve was studied and discussed to analyze the interfacial contact between the tool and the hinge. A significant damage was detected in different areas of the obtained piece. Likewise, a numerical study of the rolling process was achieved. The simulation of the process was developed using finite element code ABAQUS. The follow up of the contact pressure was completed in order to reveal the zones where the high values occurred during the rolling process. The localization of the zones where the contact pressure was important agrees with the localization of the damaged areas in the hinge obtained from the experimental apparatus.