Longitudinal and shear strain development in cold roll forming

Panton, S.M.; Duncan, J.L.; Zhu, Shengxin

doi:10.1016/0924-0136(96)02333-3

Cited by 55 publications

(23 citation statements)

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“…They found a continuous rise of longitudinal strain in the strip just ahead of each roll stand and comparison of their numerical work to previous experiments showed an approximate deviation of 10%. Around the same time Panton et al (1996) also predicted the strain distribution in a cold roll forming process. Experiments using strain gauge rosettes showed an increase of longitudinal strain on the strip surface before each roll stand, and a drop after each roll stand, and a continuous increase in shear strain throughout the forming process.…”

Section: Introductionmentioning

confidence: 94%

“…Moreover, the roll forming processes investigated have only focussed on sheets with a very large width to thickness ratio, in which shear stress effects can almost be neglected. The exception is Paralikas et al (2010), who showed that reducing shear stress by up to 50% can significantly increase the quality of the roll formed product, and Panton et al (1996) who showed a continuous increase of shear strain throughout the roll forming process.…”

Section: Introductionmentioning

confidence: 99%

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Predicting plastic deformation and work hardening during V-band formation

Müller

Barrans

Blunt

2011

Journal of Materials Processing Technology

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V-Band Clamps are manufactured using a cold roll forming process consisting of six passes which plastically deform an initially flat strip by bending to produce the band's V-section. In this paper a new method of validating numerically predicted plastic deformation in a cold formed metal strip is presented. Tensile testing of samples of the band's material was used to obtain a direct link between plastic strain and work hardness of this particular material. Using this correlation, the equivalent plastic strain (PEEQ) values predicted by finite element simulations were converted into hardness values.These values were compared to experimental work, in which samples of each pass of the roll forming process were taken to determine the work hardness in the cross section of the V-band using a microhardness machine. The error in strain predicted by the numerical method and hardness obtained by testing was found to be between 0.4% and 16.9%. This error was mainly due to uncertainty in material properties and the accuracy of the measurement technique. Compared to the more classical approach of measuring strain distribution with strain gauges, this method is more precise and accurate, as it is able to pick up even small changes in strain distribution.

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Section: Introductionmentioning

confidence: 94%

Section: Introductionmentioning

confidence: 99%

Predicting plastic deformation and work hardening during V-band formation

Müller

Barrans

Blunt

2011

Journal of Materials Processing Technology

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“…Duggal et al [2] compared the FE simulation results with Bhattacharayya's experimental results. And other numerical [3][4][5][6] and experimental [7,8] studies have been performed.…”

Section: Introductionmentioning

confidence: 99%

Optimum design of roll forming process of slide rail using design of experiments

Kim

2008

J Mech Sci Technol

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In the design of the roll forming process, design errors can be determined in advance by using an FE simulation tool such as SHAPE-RF. In the case of a product such as a slide rail having a complicated shape and requiring highprecision forming, a standard is necessary for quantitatively evaluating the quality of the formed shape. In the analysis of the roll forming process of a slide rail, the pass having the largest deformation is designated as the target pass and the positions and shapes of the rolls are set as design variables. A minimum number of simulations was performed by using the table of orthogonal arrays. A cost function was obtained from the results by using the design of experiments such as the response surface method and it was minimized for satisfying the design constraints. By improving the design of the target pass, the shape of the final product approaches that intended by the designer.

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“…In roll forming, the transverse strains at the surface of longitudinal bends may be of the order of 20% [14] while the longitudinal strains that cause some shape defects such as bow, end flare, wrinkling and twist are much lower and usually less than 1% [15]. It is important therefore to know the material behaviour in the rolling direction at very small strains near the elastic plastic transition.…”

Section: Introductionmentioning

confidence: 99%

Bending behaviour and oil canning in roll forming a steel channel

Weiß

Abeyrathna

Gangoda

et al. 2017

Int J Adv Manuf Technol

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In roll forming a wide flat channel, problems were experienced with wrinkling, or 'oil canning' in the web. This is a common shape problem in roll forming wide panels that have flat regions in the profile. Coils from four different suppliers were used in production; with three of these, wrinkling could be controlled, but one coil had to be discarded. Tensile tests performed on all materials did not identify major differences in the coils although one material showed a slight indication of ageing. Free bending tests were performed with a new standalone bend tester specifically developed for material characterisation on the shop floor. The bending tests performed on strips cut in the longitudinal direction showed a greater difference between coils; the material giving unacceptable wrinkling had a significantly higher moment curvature characteristic indicating substantial ageing. All materials showed some coil set and the bending properties depended on the direction in which the specimen was bent, i.e. in the same or opposite direction to the coil set. A finite element analysis was performed on the process which indicated significant plastic deformation in the flange, but very little in the web. Possible links between the unusual bending behaviour and oil canning in the web are suggested and the work indicates the desirability of performing free bending tests in addition to the customary tensile testing in roll forming applications.

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Longitudinal and shear strain development in cold roll forming

Cited by 55 publications

References 1 publication

Predicting plastic deformation and work hardening during V-band formation

Predicting plastic deformation and work hardening during V-band formation

Optimum design of roll forming process of slide rail using design of experiments

Bending behaviour and oil canning in roll forming a steel channel

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