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Simulation application is aimed at improving process technology methods, improve product quality, master the process of cold roll forming, reduce the roll repair and modify the design, save production commissioning costs. Cold roll forming process simulation is inseparable from the experience of roll designers and molding equipment installation and commissioning process. Separated from the cold roll forming process experience and process knowledge of the simulation is meaningless, but also in the practical application of serious consequences. Designers must be trained to become an expert in finite element simulation technology, simulation software must be used to cold roll forming designer's terminology. The roll development cycle is sometimes months long, but usually only a few weeks. Therefore, a set of roll design can only be used for a maximum of one to two weeks, which also allows time for roll processing (turning, grinding, hardening). Even with the use of advanced software and high-speed personal computers, the cold forming process of finite element simulation will take several hours or even days. Simulation calculation time can be minimized by the following methods: pre-optimization of roll sets with simulation analysis model; optimization of roll sets with finite element analysis. The best way is to use the cold forming industry's professional software package for analysis.

The first step in roll optimization is geometric simulation. The geometric characteristics of the system must take into account factors including: molding curve, roll diameter, plate thickness, cross-section shape, roll type and part of the material properties. The main goal of the simulation is to determine the minimum number of passes to be formed according to the requirements of the customer's product and to distribute the forming work smoothly among these passes. Simulation takes only a few seconds to complete the calculation of each optimization variable, helping roll designers from the initial concept to quickly determine the number of optimized passes and forming process sequence. The main idea of the simulation is that the surface shape of the deformation zone between neighboring passes can be described by a specific deformation curve. The deformation curve is a truncated section of the edge of a formed section before it proceeds to the next pass. It is conceivable that describing the deformation curve in terms of a straight line is an oversimplification and does not correspond to the actual situation. In the past, there has been a lot of research on describing the shape of the deformation zone with sinusoidal curves and polynomial functions, and a large number of experiments and finite element simulations have been carried out to make the results of these researches more in line with actual engineering. The software can now analyze the deformation length based on the deformation that occurs in the forming direction and the cross-section should be adjusted.

In order to validate an already optimized roll design, finite element simulation is necessary. The goal of simulation, which is an important part of quality management, is to validate and verify the roll design and to seek solutions to specific problems in cold forming technology. Finite element simulation has been applied in the following aspects of cold roll forming: welded pipe industry: rolls for multi-specification plate thickness, side stand roll forming, release angle, side wave of the strip after the open hole pattern, weld quality, roll abrasion (caused by excessive localized contact pressure), free deformation, sizing quality, weld compensation, and so on. Pressure plate sections: pocket waves, thinning of bending domains, arching of straight members, strip edge waves, non-ideal metal flow, etc. Open and Closed Sections: Includes all of the above for welded tube forming and pressurized plate sections, plus some unique issues such as pre-punched deformation, material hardness, bending springback, contour dimensions such as height/width/thickness ratios.

Finite element simulation results and information can be used to test the roll design and further optimization. In most cases, the cold roll forming company itself does not have such a professional inspection institute. Even if there is a research institute, due to the finite element analysts and cold roll forming designers professional language differences, it is difficult to effectively cooperate with the study. Therefore, the use of improved for cold-formed finite element simulation software design is a good choice. Such software it can automatically establish the finite element simulation model: generate enough units, reasonable boundary conditions, optimized simulation settings!

In addition, the finite element simulation software can be used to express the results of cold roll forming terminology more clearly. Users can use the operation of the virtual cold roll forming machine. In the past, often need to be carried out in the actual test, can now be done using simulation software to do, to overcome the production line must be practiced in some of the molding process limitations. It should be noted that the simulation software can be carried out in the roll design stage. This saves the following costs: production costs for unwanted rolls, rework costs for defective rolls, installation and commissioning time, downtime for repairs, and increased know-how and experience for future project development.

Industrial applications have proven the need for quality management: Scanning of the geometrical profiles of used rolls and rolls after a production cycle. Finite element simulations with actual roll geometry data can provide cold forming engineers with realistic information about the cold forming line. Roll wear and critical state can be found through maintenance. Stable use of rolls can not only reduce