Reducing the Metal Consumption of the Formwork Profile for Monolithic Construction

The article discusses the possibility of reducing the metal consumption of formwork for monolithic construction by reducing the thickness of the profile wall and increasing the mechanical properties of the steel grade from which it is made. Using strength analysis in the SolidWorks program, its operational properties and safety factor were assessed. Strength analysis of the formwork profile confirmed the possibility of moving from steel grade St3 (DIN 17100) with a thickness of 3.00 mm to steel grade 09G2S (DIN 9MnSi5) with a thickness of 2.20 mm. Simulation of profile loading during operation in the SolidWorks program showed that changing the steel grade and thickness leads to an increase in the safety factor. Formwork with a modified profile will not only not lose its strength properties, but may also have an increased service life. To design technologies for roll forming thin-walled profiles from blanks, a model was developed in the QForm program. Checking the adequacy of the developed model by comparing wear areas and contact zones showed its high convergence with the real process. Based on simulation in the QForm program, calibration of stands was developed for the production of profiles from steel grade 09G2S (DIN 9MnSi5) with a wall thickness of 2.20 mm from a workpiece (electric-welded pipe). The effectiveness of the proposed calibration is confirmed by comparing the profile obtained from the simulation with a reference sample.