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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

(OP)
Dears,

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.

https://res.cloudinary.com/engineering-com/image/upload/v1574873516/tips/Immagine_27_zjqgyu.bmp

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.

https://res.cloudinary.com/engineering-com/image/upload/v1574873678/tips/Immagine_28_pmskrx.bmp

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

https://res.cloudinary.com/engineering-com/image/upload/v1574873874/tips/Immagine_29_zjf8ec.bmp

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,

Ivan

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