Success Story: Reusing a Rolling Machine to Manufacture a New Part

1. Introduction

A metalworking company had a rolling machine that had fallen into disuse because the original rollers were designed for a discontinued part. In order to take advantage of this machine and reduce costs, the client was looking to manufacture a new part using the existing equipment. MFS was in charge of the entire process, from the specification of the part to the generation of shop drawings to manufacture the new rollers.

2. The Challenge

The design of the rolling process presented several key challenges:

• Define the geometry of the "rolling flower" to correctly describe the deformation of the sheet at each step of the process.
• Characterize the material by means of tension tests to obtain the mechanical parameters required in the simulation.
• Validate through finite element simulations that the part could be manufactured without defects, ensuring adequate deformation and avoiding failures such as collapse or wrinkles.

3. Results and Benefits

Based on the analysis and simulation, new rollers suitable for manufacturing the required part were designed. The results of the project include:

• Reuse of the existing roller , eliminating the need for investment in new machinery.
• Design of new rollers with optimized geometries based on finite element simulations.
• Manufacturing and installation of the rollers , currently in the testing phase at the client's plant.

4. Conclusion

This case demonstrates the impact of applying advanced technology in sheet metal forming. Thanks to an approach based on simulation and experimental validation, the client was able to leverage its existing equipment and reduce costs without compromising the quality of the new part. The implementation of engineering and modeling tools allows for process optimization, risk minimization, and the acceleration of the adoption of efficient solutions in the industry.