The influence of residual stress on a roll forming process

Abvabi, Akbar; Rolfe, Bernard; Hodgson, Peter; Weiß, Matthias

doi:10.1016/j.ijmecsci.2015.08.004

Cited by 81 publications

(36 citation statements)

References 25 publications

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“…Roll-bending process of ring is similar to three-roller bending process of beam, as shown in Figure 12. It could introduce tensile residual stress at the material surface and compressive residual stress in the mid-plane, as described by Abvabi [19]. While the surface of 2219 Al alloy ring presented compressive residual stress and the mid-plane presented tensile residual stress, after quenching.…”

Section: Discussion On the Evolution Of Quenching Stress During The Rmentioning

confidence: 94%

“…The result revealed that cold rolling transforms near-surface residual stresses from large compression to large tension along the rolling direction. And Abvabi et al [19] investigated the influence of residual stress on a roll bending forming process of DP780 steel plates. The result indicated that a thickness reduction rolling process led to the introduction of tensile residual stress at the material surface, and compressive residual stress in the mid-plane of the plate.…”

Section: Introductionmentioning

confidence: 99%

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Residual Stress Relief in 2219 Aluminium Alloy Ring Using Roll-Bending

et al. 2019

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Relieving the residual stress in components is essential to improve their service performance. In this study, a roll-bending process was proposed to reduce the quenching residual stress in a large-size 2219 Al alloy ring. The roll-bending effect on quenching residual stress was evaluated via the finite element method (FEM) combined with experiment. The effect of radial feed quantity, friction coefficient, and roller rotational speed during the roll-bending process on quenching residual stress was analyzed. A set of optimized roll-bending parameters with radial feed quantity, friction coefficient, and roller rotational speed was obtained. The results reveal that the best reduction rates of circumferential and axial residual stress reached 61.72% and 86.24%, respectively. Furthermore, the difference of the residual stress reduction effect between the roll-bended ring and the three-roller bended beam was analyzed.

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Section: Discussion On the Evolution Of Quenching Stress During The Rmentioning

confidence: 94%

Section: Introductionmentioning

confidence: 99%

Residual Stress Relief in 2219 Aluminium Alloy Ring Using Roll-Bending

et al. 2019

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“…Previous studies revealed that residual stress and the resulting change in bending yield stress can significantly influence shape defects such as bow and flare that are common in the roll forming process [25]. Nevertheless, as all coils show the effects of coil set, it is unlikely that this is the major cause of the oil canning problem in one material.…”

Section: Discussion On the Processmentioning

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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“…They are basically separated in two different classifications depending on the manufacturing process, being produced by hot-rolling or cold forming (1,2), which also lead to its main differences in material properties (3)(4)(5)(6) and residual stresses (4,(6)(7)(8)(9)(10). They are basically separated in two different classifications depending on the manufacturing process, being produced by hot-rolling or cold forming (1,2), which also lead to its main differences in material properties (3)(4)(5)(6) and residual stresses (4,(6)(7)(8)(9)(10).…”

Section: Introductionmentioning

confidence: 99%

Preliminary study on the impact of initial imperfections on the post‐buckling rotation of square hollow sections in uniform bending

Müller

Taras

2019

ce papers

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With increasing use of high-strength steel grades, the need for more accurate design specifications arises, with the aim of fully exploiting the material benefits and create economic advantages. According to Eurocode 3, the maximum rotational capacity is limited and linked to the definition of cross-sectional classes. For class 1, the rotation θ is assumed to be "infinite", while it drops significantly for class 2 and 3 to a maximum rotation of θpl and θel, respectively. In reality, in spite of their lower hardening capacity and ultimate strains, high-strength steel sections display a nonnegligible rotational capacity that exceeds these code predictions, which were developed for mild steel and with a level of analysis in mind that is suitable for hand calculations. For an increased use of high-strength steel sections, it is thus very important to understand and to be able to predict a more realistic deformation and rotation capacity, with the aim of implementing the findings in tools for advanced, FEM-based Design by Analysis (DbA) approaches. As an initial step in this direction, the proposed paper shows the results from numerical calculations on the rotational capacity of HSS rectangular hollow sections. The numerical results are calibrated against laboratory tests. Consequently, different rectangular cross section dimensions but also variations of the steel grade and the thickness are chosen and calculated in the finite element program ABAQUS.

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The influence of residual stress on a roll forming process

Cited by 81 publications

References 25 publications

Residual Stress Relief in 2219 Aluminium Alloy Ring Using Roll-Bending

Residual Stress Relief in 2219 Aluminium Alloy Ring Using Roll-Bending

Bending behaviour and oil canning in roll forming a steel channel

Preliminary study on the impact of initial imperfections on the post‐buckling rotation of square hollow sections in uniform bending

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