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Roll-forming process with ABAQUS: problems with interaction with analytical surfaces

Roll-forming process with ABAQUS: problems with interaction with analytical surfaces

Roll-forming process with ABAQUS: problems with interaction with analytical surfaces


I'm trying to simulate a cold roll-forming process for a metal sheet. I started trying with static general analysis. In order to simplify the model and to avoid possible preliminary problems, I started considering only two rolls groups defined as rigid analytical surfaces.


After initial step, I have defined "interference fit" step in order to applying preliminary pressure between sheet and the rolls of the first stations. In a further step, I' ve appliyed rotation at each rolls and the first rolls group push forward the sheet efficiently thanks to the initial pressure.


Problems occur following: interaction between sheet and second group of rolls doesn't work and pairs interpenetrate one another.


Interactions between sheet surfaces and analytical rigid surfaces are defined as "surface to surface" with tangetial penalty friction and normal hard contact. This is the same defition I used between first rolls group and sheet and it works correctly for these rolls. I think the problem could be the initial clearance between pairs.
This problem could disappeare if I use deformable definition for the rolls, but I want to mantain analytical rigid surfaces in order to reduce computational costs for my simulation.

How can I fix it?

Thanks in advantage,
Best regards,


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