Optimising roll forming simulation in Abaqus: A computational study

Roll forming is a critical manufacturing process due to its complex mechanics and the sequential deformation of metal strips, which pose significant computational challenges. This study presents an optimised simulation strategy for roll forming using Abaqus 2023, focusing on reducing computation time while maintaining result accuracy. The proposed approach combines a tailored conformal mesh partitioning scheme, material model refinement based on experimental tensile data, and element type selection to enhance simulation efficiency. Unlike previous studies, this work integrates experimental validation using force measurements and geometry scanning from an industrial roll-forming process, confirming the accuracy of the numerical model. Additionally, the entire model setup, including meshing and boundary condition definition, is fully scripted in Python, enabling rapid and reproducible model generation for various profile geometries. This study provides a quantitative trade-off analysis between mesh resolution, accuracy, and computational cost. These findings are directly transferable to industrial design workflows, offering a practical method for accelerating simulation-based roll-forming process development.