A novel approach to springback control of high-strength steel in cold roll forming

Cheng, Jiaojiao; Cao, Jian; Zhao, Qianchuan; Liu, Jiang; Ning, Yu; Zhao, Rongguo

doi:10.1007/s00170-020-05154-8

Cited by 28 publications

(9 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Edge buckling is a common defect in the roll forming products, especially when large deformations occur, such as large bending angle increment. 29 To avoid such defects, a pair of pre-form rolls at the beginning of the line were used. Depending on the bending angle increment, different numbers of forming stand were installed for each test.…”

Section: Experimental Setup Featuresmentioning

confidence: 99%

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Bidabadi

Naeini

Safdarian

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

In spite of product quality increase in the cold roll forming process by previous practical researches for defects prevention, there are some ill-considered defects such as over-bending, which diminished the product quality in the open section products of this process. This defect which happens by superfluous bending of sheet in the forming stand not only lead to defective products, but also trigger other defects such as edge wrinkling. Since in an elaborate process such as cold roll forming, forming parameters play an active role in defect prevention, the effect of some important parameters is investigated on the over-bending defect and product bending angle by doing 68 experimental tests and numerical simulations in the present study. The list of parameters which are investigated includes bend angle increment, flange width, strip thickness, radius of bend, strength of the materials, and inter-distance between successive stands. In addition, the reason behind the effect of each parameter on the accuracy of the bending angle is laid out. Results show that over-bending defect can be compensated or even eliminated by decreasing the bending angle in each stand, a technique called bending angle increment. Increasing the number of forming stands from two to five causes the over-bending to decrease from 6° to 0°. With bending angle increment being the most impactful factor, bending radius, flange width, and strip thickness have a decreasing impact on over-bending. This study also brings forward a reverse relationship between the strength of the material and the intensity of over-bending. The inter-distance between successive stands was found to have the least effect on over-bending. Results highlight the importance of pre-form rolls at the beginning of the roll forming line. Without the usage of pre-form rolls, the folding of strips on a 60° angle, cannot be done in one stand.

show abstract

Section: Experimental Setup Featuresmentioning

confidence: 99%

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Bidabadi

Naeini

Safdarian

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Zeng et al optimized the design of each station using the response surface method Replacing Paper sleeve Aluminum sleeve and found that the optimized roll diameter and forming angle increment were effective in avoiding the U-channel edge wave phenomenon, and the springback was also controlled to a minimum value [10]. To control the springback of high-strength steels with cap sections, Jiao-Jiao et al proposed an umbrella angle adjustment method in combination with angle compensation [11]. Wiebenga et al performed robust optimization of the cold roll forming process to compensate for product defects, of which effectiveness was proved by both experimental and numerical results [12].…”

Section: Introductionmentioning

confidence: 99%

A study of transverse bowing defect in cold roll-forming asymmetric corrugated channels

Chen²,

Wei³

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The transverse bowing greatly affects accuracy of the roll forming asymmetric corrugated channels (ACC). In order to control this defect, the paper first elucidates its mechanism of the production. Then the transverse bowing is explored by finite element method (FEM) using ABAQUS 2016 software and the effects of the forming parameters are analyzed. Also, a linear regression model is built using Minitab 19 software to evaluate their effects, of which standard values are measured by Pareto chart. It is observed that the number of forming channels has the greatest effect, followed by the roll gas and bending angle, and the friction coefficient has the least. Finally, to decrease the transverse bowing defect (TBD), the dominant forming parameters are optimized according to the evaluation results and the operating conditions. And the results of simulation and optimization are verified by experiments, respectively. This research shows that the TBD can be greatly controlled by the optimization of three dominant forming parameters including the roll gap, bending angle and inter-station distance for given ACC.

show abstract

“…Roll forming (RF) is a well-known process for the manufacturing of components with a uniform crosssection for applications in the automotive and building industry [3,4]. It allows the forming of di cult to form materials to complex geometries with minimum shape defects but is limited to long pro les of constant cross-section [5]. To enable the roll forming of structurally optimised pro les that vary in width and depth over the length of the part, Flexible Roll Forming (FRF) has been developed, In FRF, the pre-cut blank is fed through several roll stands, where some rolls stay stationary similar to the conventional roll forming process while others rotate and translate axially to achieve variability in the cross-section shape [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Prototyping of straight section components using incremental shape rolling

Essa

Abeyrathna²,

Rolfe³

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Flexible Roll Forming (FRF) allows the forming of components with a variable cross-section along the length of the component. However, the process has only limited application in the automotive industry due to wrinkling in the ange which currently prevents the forming of high strength steels and limits the part shape complexity. This paper presents a new forming technology, Incremental Shape Rolling (ISR), where a pre-cut blank is clamped between two dies and then a single forming roll is used to incrementally form the material to the desired shape. The new process is similar to some Incremental Sheet Forming (ISF) approaches but with the difference that Incremental Shape Rolling (ISR) allows the manufacture of longitudinal components from high strength metal sheets. In this work, a numerical model of the ISR of a straight section is developed. Experimental prototyping trials are performed and are used to validate the numerical model which is then applied to analyse the new forming process. The results show that in ISR, tensile residual strains are developed in the ange. Flange wrinkling is observed and directly linked to the number of forming passes that are used in the process.

show abstract

A novel approach to springback control of high-strength steel in cold roll forming

Cited by 28 publications

References 28 publications

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

A study of transverse bowing defect in cold roll-forming asymmetric corrugated channels

Prototyping of straight section components using incremental shape rolling

Contact Info

Product

Resources

About