Cold Roll Forming Process Design for Complex Stainless-Steel Section Based on COPRA and Orthogonal Experiment

Wang, Jing; Liu, Hua‐Min; Li, She-Fei; Chen, Wanjun

doi:10.3390/ma15228023

Cited by 5 publications

(5 citation statements)

References 18 publications

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“…Ultra-high strength steels have been widely applied in the manufacturing of thin-walled structures to achieve better performance in various working environments. Due to their difficult-to-form characteristic at room temperature, ultra-high strength steels are usually processed through the traditional multi-pass roll forming process to achieve complex cross-sectional profiles [1]. However, increasing requirements for compact geometrical profiles with small springback and sharp bending radius usually bring out additional roll configurations; the tendency towards customized geometry design also demands the redesign of forming dies.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on process parameters of laser-assisted robotic roller bending of a thin-walled structure

Qiu,

Xu,

Liu

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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Laser-assisted robotic roller forming (LRRF) combines the process capabilities of robot-based manufacturing and laser-assisted forming. In this work, the LRRF process was applied to bending DP1180 steel sheets to thin-walled structures designed for seat trails. Comprehensive experimental investigations were conducted to explore the influences of laser power, forming passes and scanning speed on the forming forces, springback and bending radii of final parts. Experimental results show that the effects of process parameters on the springback and bending radii are similar to those on the forming forces, while forming passes make an insignificant difference to the springback. The optimized process window was subsequently determined out of the balance between geometrical accuracy and experimental efficiency. By applying the optimized process parameters (laser power of 750 W, 6 forming passes, scanning speed of 5 mm/s), the peak force during LRRF was reduced to ∼2.1kN. Meanwhile, a thin-walled profile with higher precision was achieved. Specifically, the springback angle was reduced to ∼4.1° and a compact profile with a radius-to-thickness ratio of ∼1.0 was obtained.

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Section: Introductionmentioning

confidence: 99%

Experimental investigation on process parameters of laser-assisted robotic roller bending of a thin-walled structure

Qiu,

Xu,

Liu

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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“…Murugesan et al [17] investigated the presence of longitudinal bow, the reason behind the flange height deviation, springback, and identification of the thinning location in the cold roll forming of symmetrical short U-profile sheets. Wang et al [18] investigated the effects of roll spacing, friction coefficient, diameter increment, and linear velocity on the maximum longitudinal strain at the edges by using the orthogonal experimental method and proposed a floating roll device suitable for asymmetric large-depth complex sections.…”

Section: Introductionmentioning

confidence: 99%

Research on the Mechanism and Processability of Roll Forming

Kang,

Sun,

Zhang

et al. 2024

Materials

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Cold bending forming is a complex forming process, and its product quality is closely related to the forming process parameters. To mitigate issues such as bulging and waviness arising from the extension of the material at the edges during the forming process of thin-walled circular tubes, a comprehensive comparative analysis was conducted on four forming methods. This analysis determined that the combined bending method is the optimal forming technique for the equipment. For the impact of different parameters on the equivalent plastic strain distribution of the product and the force on the rollers, numerical simulations were carried out using the software COPRA (COPRA FEA RF 2023.1) after designing the pattern diagram based on the integrated bending method. The results showed that different processing speeds on the equivalent plastic strain distribution and work hardening of the plate have little effect. As the spacing between the upper and lower rollers increases, the equivalent plastic strain of the plate to a certain extent and the value of the moment of the rollers is significantly reduced. Analyzing the performance characteristics of high-strength steel materials from the aspects of the thickness strain and cross-sectional forming of the plate, this verifies the advantages of forming high-strength steel plates. The numerical simulation results of this study are in good agreement with actual production experimental results.

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“…However, it is di cult to use conventional design methods developed for materials with low tensile strength (e.g., mild steel) for materials with high tensile strength (e.g., UHSS). Wang et al [14] conducted analysis and experiments with the setup angle as the variable for enhancing the formability of high-strength steel as one of the existing studies to address the issue of differences in the loads and speed of rolls. In this study, the residual stress of the bending zone and the difference in speed between the upper and lower rolls in the cross-section were reduced by controlling the setup angles.…”

Section: Introductionmentioning

confidence: 99%

Design of Roll-Forming Process for U-Profile Rail

Kim

2023

Preprint

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Roll forming is a manufacturing process that involves plastic forming via bending using a rolling motion. During roll forming, a coil or blank is formed incrementally in a stepless and continuous process with the aid of rolls to fabricate profile rails. The shape of the rolls predicted the incremental deformation in the cross-sections of the U-profile rails. However, the final shape after the roll-forming process is entirely different from the modeled parts because of the springback caused by the mechanical properties of the materials. The design of roll-forming processes has been investigated to address typical plastic defects, such as springback and residual stress. Roll flower diagrams were developed in the initial stage of the design of the roll-forming processes. These diagrams show the cross-sectional shapes of the product at various stages of the process, superimposed on each other. The diagrams contain information for the process design, including the incremental deformation, number of passes, and setup angle of the rolls. There is no standard method for designing roll–flower diagrams. These were developed based on the designer’s experience with the material properties and multiple shapes. In this study, roll flower diagrams were designed using the developed formula, considering constant radius-of-curvature or length-of-curvature zones in the cross-sections of U-profile rails. Roll-forming processes were simulated using the commercial FEM code Abaqus to measure the loads of the rolls, springback of the blank, and residual-stress history. Simulation and experimental results regarding the shapes of the U-profile rails were compared to validate the process design method.

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Cold Roll Forming Process Design for Complex Stainless-Steel Section Based on COPRA and Orthogonal Experiment

Cited by 5 publications

References 18 publications

Experimental investigation on process parameters of laser-assisted robotic roller bending of a thin-walled structure

Experimental investigation on process parameters of laser-assisted robotic roller bending of a thin-walled structure

Research on the Mechanism and Processability of Roll Forming

Design of Roll-Forming Process for U-Profile Rail

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