Flange Wrinkling in Flexible Roll Forming Process

Kasaei, Mohammad Mehdi; Naeini, Hassan Moslemi; Abbaszadeh, Behnam; Mohammadi, Mohammad; Ghodsi, Mojtaba; Kiuchi, Manabu; Zolghadr, Reza; Liaghat, Gholamhossein; Tafti, Rohollah Azizi; Tehrani, Mehran

doi:10.1016/j.proeng.2014.09.158

Cited by 35 publications

(14 citation statements)

References 3 publications

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“…Larenga and Galdos for investigation of the web waring, applied local heating during FRF, most local heating effect is achieved when before the start of forming, the wings of the whole area should be heated [4]. Kasaei and et.al studied wrinkling on the transition zone using finite element analysis, according to the results of the study, wrinkling occurs when the longitudinal compressive strain is less than the required compressive strain calculated by mathematical modeling to obtain geometry considered in the transition zone [5]. Mohammadi and et.al used a finite element simulation to examine how to create web warping, the results showed that main cause of occurrence of this defect not apply enough strain on the edge of the wings of the profile in the transition zone [6].…”

Section: Fig 2 the Verticality Of Rollers In Different Positions On The Bending Curvementioning

confidence: 99%

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Panahizadeh

Asl

Saeedi

et al. 2021

Preprint

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The Flexible Roll Forming (FRF) process with the ability to produce parts with variable width and depth was formed to be used in industries such as automotive, construction, and similar industries. One of the disadvantages of this process is the spring-back defect, which prevents the desired profile from being achieved. In this paper, experimental and numerical analysis of the spring-back phenomenon using Hill, Barlat, and Von Mises yield criteria. Also, the effect of bending angle, material, and sheet thickness parameters on this defect was investigated. The process for the three types of 1050 aluminum, low carbon steel, and 430 stainless steel was simulated using the VUMAT subroutine of Abaqus software. In these simulations, for each material, three thicknesses of 0.4, 0.7 and 1 mm with bending angles of 25 and 45 degrees were considered. Experimental experiments were performed using the FRF machine. Validation of numerical simulation results was performed by comparing experimental results. The results showed that the Barlat criterion has a more accurate prediction of spring-back than the other two criteria. The results also showed that the spring-back ratio of sheets with a thickness of 0.4 mm compared to 1 mm for low carbon, aluminum, and stainless steel are 1.5, 2.5, and 3.2, respectively.

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Section: Fig 2 the Verticality Of Rollers In Different Positions On The Bending Curvementioning

confidence: 99%

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Panahizadeh

Asl

Saeedi

et al. 2021

Preprint

View full text Add to dashboard Cite

show abstract

“…Products from this process are shown in Fig. 14 Flange wrinkling and web warping are two major failure modes in flexible roll forming [77,78]. They are caused by longitudinal compressive and tensile stresses in the inlet and outlet zones of the change in section [56] Larrañaga and Galdos [105] investigated the enhancement of the accuracy for the flexible roll forming.…”

Section: Incremental Profile Forming By Flexible Roll Movementsmentioning

confidence: 99%

Flexibility in metal forming

et al. 2018

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Flexibility in metal forming is needed more than ever before due to rapidly changing customer demands. It paves the way for a better control of uncertainties in development and application of metal forming processes. Although flexibility has been pursued from various viewpoints in terms of machines, material, process, working environment and properties, etc., a thorough study of the concept was undertaken in order to with problems of manufacturing competiveness and tackle new challenges of manufacturing surroundings. Therefore, in this paper, flexibility in forming is reviewed from the viewpoints of process, material, manufacturing environment, new process combinations and machine-systemsoftware interactions.

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“…Further details on the FRF set-up can be found elsewhere. 8 The experiments in FRF were designed in order to produce variable cross-sectional profiles with selected geometries for supporting the investigation on the occurrence of flange wrinkling. The experimental work plan is summarized in Table 2 and the enclosed schematic figure provides the notation of a typical variable cross-sectional channel profile and preform.…”

Section: Experiments In Frfmentioning

confidence: 99%

“…Very recently, Kasaei et al 8 and Yan et al 9 set up finite element models to determine the distribution and time history of strain in both constant and variable cross sections of the profiles. Both publications are major steps towards the understanding of the deformation mechanics of FRF, but the distribution and time history of stresses are not covered with the same level of detail as that of strains.…”

Section: Introductionmentioning

confidence: 99%

Revisiting the wrinkling limits in flexible roll forming

Kasaei

Naeini

Liaghat

et al. 2015

The Journal of Strain Analysis for Engineering Design

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This article presents a new understanding on the deformation mechanics of flexible roll forming and is focused on the occurrence of flange wrinkling. The presentation draws from the experimental and numerical simulation of flexible roll forming to the determination of the wrinkling limits by means of a new theoretical and experimental methodology based on the utilization of rectangular test specimens loaded in axial compression. This research work is performed in mild steel sheets and the results show that the combined evolution of the effective strain with stress triaxiality obtained from finite element modelling of flexible roll forming and from the rectangular test specimens loaded in axial compression can be successfully utilized to predict the occurrence of flange wrinkling in variable cross-sectional profiles produced by flexible roll forming. The proposed methodology can, therefore, be considered an alternative to existing approaches based on simplified analytical and numerical procedures.

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Flange Wrinkling in Flexible Roll Forming Process

Cited by 35 publications

References 3 publications

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Anisotropic Analysis of Springback in FRF Process With Variable Cross Section Using Hill and Barlat Criteria

Flexibility in metal forming

Revisiting the wrinkling limits in flexible roll forming

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