3D FEM simulation of shape rolling using an ale method

The shape rolling of stator vanes has been modelled in 3D using the finite element method. Till now only the rolling of straight vanes, which have a constant cross section, is studied. Therefore this rolling process can be considered as a stationary process. Such processes can be described as a flow problem using the Arbitrary Lagrangian Eulerian (ALE) formulation. This makes it possible to follow free surfaces and to adapt the mesh in order to avoid large element distortions, to keep or create refinements were needed. The mesh topology however remains constant during a simulation. Topics of the ALE formulation such as mesh relocation, transfer of state variables etc. will be addressed in the paper. The tools are modelled as deformable bodies, as tool deformation is the most important reason for the deviation of the vane dimensions from the required dimensions. 3D FEM simulations have been carried out of the rolling of a test vane. Some characteristic results, such as material flow, tool deformations, stresses and strains, will be shown.