Numerical Analysis of the Three-Roll Bending Process of 6061-T6 Aluminum Profiles with Multiple Bending Radii Using the Finite Element Method

The present work numerically investigates the mechanical behavior of six 6061-T6 aluminum profiles during roll bending, considering, in two specific cases, the application of the process in different bending directions (vertical and horizontal), totaling eight cases analyzed, with emphasis on the influence of multiple bending radii. Notably, two of the profiles are characterized by high geometric complexity, making their analysis particularly relevant within the scope of this study. Using the finite element method in ANSYS® (version 2022 R2) (SOLID187 element), the study expands the previously validated model to a broader range of geometries and includes an additional validation and verification stage. The results reveal: (i) an inverse relationship between bending radius and von Mises stress, with critical values close to the material’s strength limit at smaller radii; (ii) characteristic displacement patterns for each profile, quantified through specific curve fittings; and (iii) a systematic comparison among the six profiles, highlighting stress concentrations and deformations differentiated by geometry. The simulations provide criteria for predicting forming defects and optimizing process parameters, expanding the database for industrial designs with multiple extruded profiles.