The effect of process and geometric parameters on longitudinal edge strain and product defects in cold roll forming

Abeyrathna, Buddhika; Rolfe, Bernard; Weiß, Matthias

doi:10.1007/s00170-017-0164-x

Cited by 44 publications

(27 citation statements)

References 16 publications

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“…The work of Abeyrathna et al. [19,20] on roll forming of DP and MS steels showed that the peak longitudinal edge strain increases with bending angle, whereas decreases with flange length, and longitudinal bow decreases with the increase of flange length and inter-station distance. Badr et al [7] carried out an investigation on the effect of two tooling design strategies on the longitudinal bow in roll forming AHSS, and found that the longitudinal bow was reduced by 50% by assuming the constant bend radius scheme compared with the constant arc length strategy.…”

Section: Accepted Manuscriptmentioning

confidence: 99%

A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming

Sun

Xiao

et al. 2018

International Journal of Mechanical Sciences

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The performance of AHSS in chain-die forming is investigated by experiment and simulation.  The hardening model to describe the Bauschinger effect of the AHSS is established and implemented into the finite element model of chain-die forming process.  The evolutions of longitudinal strain and springback in the chain-die forming of the U-channel are investigated.  A systematic comparison between chain-die forming and roll forming of the U-channel are performed in terms of deformation mechanism, transitional surface, strain development and springback, etc.

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Section: Accepted Manuscriptmentioning

confidence: 99%

A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming

Sun

Xiao

et al. 2018

International Journal of Mechanical Sciences

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“…Conversely, the longitudinal edge strain was identified as having no effect due to the friction and roll speed. Buddhika Abeyrathna et al [ 12 ] also researched the process and the part shape factors in the cold roll forming process for examining the presence of the longitudinal peak edge strain, spring back, and bow in the formed part. Both experimental and empirical model results were showed significant variations in the forming behavior of advanced high-strength steel (AHSS) and ultra high-strength steel (UHSS) than that of other softer steel grades.…”

Section: Introductionmentioning

confidence: 99%

“…Besides, the material properties estimation, such as mechanical properties and the plastic anisotropy for the metal forming process, was not carried out in detail using the DIC technique in previously published articles. Therefore, there is still a research gap for further improvement in the cold roll forming process concerning the proper material properties estimation [ 32 , 33 , 34 , 35 ] and selecting proper forming parameters [ 11 , 12 , 36 ] for the chosen material to manufacture the quality parts without shape defects.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming

2021

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The cold roll forming process is broadly used to produce a specific shape of cold-roll formed products for their applications in automobiles, aerospace, shipbuilding, and construction sectors. Moreover, a proper selection of strip thickness and forming speed to avoid fracture is most important for manufacturing a quality product. This research aims to investigate the presence of longitudinal bow, the reason behind flange height deviation, spring-back, and identification of thinning location in the cold roll-forming of symmetrical short U-profile sheets. A room temperature tensile test is performed for the commercially available AA5052–H32 Al alloy sheets using Digital Image Correlation (DIC) technique, which allows complete displacement and strain data information at each time-step. The material properties are estimated from the digital images using correlation software for tested samples; the plastic strain ratios are also calculated from samples at 0°, 45°, and 90° to the rolling direction. The tested sample’s surface morphology and the elemental analysis are conducted using scanning electron microscopy (SEM) method and energy-dispersive X-ray spectroscopy (EDS) analytical technique combined with element mapping analysis, respectively. The cold roll forming experiments are systematically carried out, and then finite element analysis is utilized to correlate the experiment with the model. The performed cold roll forming numerical model outcome indicates a good agreement with the experimental measurements. Overall, the presented longitudinal strain was observed to influence the geometry profile. The spring-back is also noticed at the profile tail end and is more pronounced at high forming speed with lower strip thickness. Conversely, while the forming speed is varied, the strain and stress variations are observed to be insignificant, and the similar results also are recognized for the thinning behavior.

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“…Chongthairungruang et al [16] found that higher pre-deformation state significantly improves the springback effect of strip through finite element simulation. Abeyrathna et al [17] investigated the influence of geometric parameters on longitudinal edge strain through numerical analysis and experimental verification method, and obtained the influence of geometric parameters on springback. Toros et al [18] applied Hill'48, Barat-89 and YLD2000-2D material models to predict the springback characteristics of TRIP800 advanced high strength steel (AHSS), and found that YLD2000-2D has the best predictive ability for the springback of V-shaped mold in CRF process.…”

Section: Introductionmentioning

confidence: 99%

“…Fig 17. The effect of holes on the springback a springback angles at each end face, b elastic strain of the top nodes at each end face…”

mentioning

confidence: 99%

Experimental and numerical investigation of the effect of holes on the springback in cold roll forming of UHSS

Liu

Pan

liu

et al. 2021

Preprint

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Ultra-high strength steel (UHSS) pre-notched sections are getting growing popularity in the automotive industry with the development of automotive lightweight. However, the springback of UHSS products is large, and the existence of holes also has an effect on the springback. Accurate prediction of springback of UHSS pre-notched products in cold roll forming ( CRF ) is a key issue to be solved. In this paper, the effect of holes on the springback of UHSS in CRF is discussed by simulation and experiment. The finite element model of pre-notched car threshold was constructed, and its accuracy was validated by continuous CRF experiment. The mathematical model of variable elastic modulus determined by tensile tests of martensite (MS) 1300 was applied in finite element model. The accuracy of springback was improved by 15% in the hole region by using variable elastic modulus . Several forming schemes were designed to research the effect of different features on the springback in the hole region. The results show that the existence of holes reduces the springback and the effect is different at different positions of the car threshold. The springback in the hole region decreases with the increase of the number of stands, the strip thickness and the hole diameter, and with the decrease of the distance between stands and the distance between holes. This study provides a help for reducing the influence of holes on the springback and improving the forming precision of pre-notched sections in the actual production of CRF.

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The effect of process and geometric parameters on longitudinal edge strain and product defects in cold roll forming

Cited by 44 publications

References 16 publications

A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming

A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming

Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming

Experimental and numerical investigation of the effect of holes on the springback in cold roll forming of UHSS

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