One of the most important causes of steel sections failures are the residual stresses. They are those stresses that are locked in the profiles without of application of any service or internal loads. They influence the material properties of rolled materials and as a consequence the propagation of cracks. Based on the received results, three dimensional finite element analysis of the roller straightening process of chosen H-section was found to be promising for the designing of optimal setting of each roll.Three dimensional finite element modelling of the roller straightening process of H-section beams is presented in the paper. An explicit-dynamic method by using ABAQUS solver was adopted to realize the feeding of H-sections into the intermeshed rolls by rotating the upper rolls and to accomplish the calculation under condition of frequent contact between H-section and roll interface. Realistic kinematic boundary conditions are implemented in the research; the longitudinal movement of the product through straightening machine achieved by the rollers and the friction. For the constitutive equation of the material, elastic-plastic hardening low was used. The effect of the roll gap on the straightness of the chosen H-section after straightening process was examined. Equivalent stresses, strains, forces and torques parameters were calculated as well. Well known global effects eg. increasing of the web height, flapping of the H-section towards rollers occurs in the research as well. The residual stress can be reduced by reasonable straightening process and it contributes to improving the quality and secure life of H-sections.Keywords: roller straightening, residual stresses, H-sections, elastic-plastic material, numerical simulations
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