本文主要是以DEFORMTM有限元素軟體模擬U型鋼片連續道次成型與單一道次成型以確認單一道次模擬的是否可取代連續道次模擬之研究。
因DEFORMTM 軟體對於網格元素上的限制,故使用較短素材120mm通過所有的成型站以模擬工廠實際連續成形方法。 輥輪間隙固定為0.3mm；輥輪轉速為20 rad/sec；彎曲角度的方法為將成型角度平均除以成型站數。有三種輥輪成型方式被選擇分別為6站，9站，與12站。在模擬的過程中,有兩種現象會產生.Case A，素材通過單一成型站。Case B，素材會通過兩個成型站。因為在模擬過程中素材的兩端會有拉應力與扭力。Case B的模擬比Case A像實際的製程，並計算應力與應變在U型斷面的Tip部中可發現Case A比Case B低約15%。
從Case B的每站的結果可以得知，12站的成型應力最小，9站次之，6站最後。因為最少的成型站可以節省最多的成本與成型時間，但6站成型因於材料的邊緣產生皺摺得到較大的應力與應變，但沒發生在9站與12站成型。所以9站成型方式是比12站較適當的設計。12站各站成型角度為7.5°，9站為10°， 6站為15°。

The objectives of this paper were to investigate the simulation and design of continuous multiple-station rolling forming process for a U-Section Steel Bar by CAE software-DEFORMTM. Due to the limitation of elements number, using a short strip 120mm went through all the stations to simulate the real continuous rolling forming on factory. The roller gap was fixed as 0.30mm, roll speed was 20 rad/sec, and progressive angles were all equal for each rolling process, which were the formed angle divided by by the number of station. Three rolling processes were selected with 6,9,and 12 stations, respectively.
During simulation processes, two cases occurred. Case A, the strip was through a single station. Case B, the strip across two stations. Because the strip laterals side was stretched and twisted during the process. The model of case B closer to the practical process than case A, and the calculated stress and strain on the tip of U section for case A were lower than these for case B by up to 15%.
From the result of case B for each process, the stress for 12-station process was smallest, 9-station process second and 6-station process next. Because less-station can save larger cost and forming time, but the bigger stress and strain for 6-station caused wrinkles on lateral sides, not found on 9-station and 12-station. Therefore, 9-station process was a more suitable design than 12-station process, smaller stretched and twisted and stress. The progressive angles for 12-station was 7.5°, 10° for 9-station and 15° for 6-station.

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