scholarly journals Effect of Geometrical Factors on Torsion in Cold Roll Forming of the Lower Side Beam of a Car

2021 ◽  
Vol 11 (17) ◽  
pp. 7852
Author(s):  
Yesong Wang ◽  
Xiaodong Xu ◽  
Bobo Ren ◽  
Jiang Liu ◽  
Rongguo Zhao
Keyword(s):  
Sheet Material ◽  
Three Dimensional ◽  
Roll Forming ◽  
Lower Side ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Side Beam ◽  
Metal Forming Process

Cold roll forming is a continuous metal forming process used to produce a large variety of profiles. A significant product of cold roll forming is asymmetric profiles, whose application is expanding in the construction of cars, houses, bridges, etc. Torsion is one of the common defects in the cold roll forming process of asymmetric section steel and sometimes seriously affects cold roll forming products. With the development of the economy and technology, many asymmetric cold roll-formed parts are being gradually applied to automobiles. Three-dimensional finite element analysis models of 12 stands with 700L sheet material were carried out using the professional COPRA RF and MSC MARC software, taking the lower beam of an automobile as the research object. Five geometric factors of the lower side beam were researched, and the influence rules of different geometric elements on the forming torsion were analyzed. We found that with the increase of web width, flange width, and vertical edge height and the decrease of the corner radius and strip thickness, the torsion defects of cold roll forming were improved to different degrees. The results also showed that the width of the flange has the most significant effect on torsion.

418 Cold roll forming process of wrought magnesium alloy using finite element analysis

2014 ◽  
Vol 2014.22 (0) ◽  
pp. 163-164
Author(s):  
Shintaro AKANUMA ◽  
Tomoya SUZUKI ◽  
Hayato ASO ◽  
Bunkyo KYO ◽  
Shinichi NISHIDA ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Magnesium Alloy ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Wrought Magnesium Alloy ◽  
Roll Forming Process

Simulating the UltraSTEELTM Surface Dimpling Process

2009 ◽  
Vol 410-411 ◽  
pp. 449-456 ◽  
Author(s):  
Chang J. Wang ◽  
Diane J. Mynors ◽  
Martin English
Keyword(s):  
Test Performance ◽  
Steel Strip ◽  
Plastic Region ◽  
Metal Sheet ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Spatially Distributed

The UltraSTEELTM process, developed by Hadley Industries Plc (Hadleys), is a novel surface dimpling process used on steel strip prior to cold roll forming. This dimpling process increases the strength of the final rolled products and enhances other product properties such as fire test performance and screw retention. Reported in this paper are the results of finite element analysis conducted to simulate the application of the spatially distributed dimple pattern to the metal sheet prior to the cold roll forming process. The model contains a representation of the two rotating rolls that plastically deform, imparting the spatially distributed dimple pattern on the sheet as it moves between them. The simulation results are compared with industrially processed UltraSTEELTM steel sheet. Consideration is given to the plastic region developed in the dimples and the effect of rolling action on the regions. The dimensional change of the metal sheet is also discussed.

Velocity Control with SGARC 440 Alloy in the Roll Forming Process

2015 ◽  
Vol 1095 ◽  
pp. 894-897
Author(s):  
Ya Zhang ◽  
Dong Hong Kim ◽  
Dong Won Jung
Keyword(s):  
Theory And Practice ◽  
Roll Forming ◽  
Velocity Control ◽  
Spring Back ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Strip Metal ◽  
Roll Forming Process

Cold roll-forming of metal sections is a significant field in advancing forming of strip metal, and the forming processes are influenced by many factors. The scientific design of passes is worked out by combining theoretical analysis with finite element analysis, in accordance with the principles of cold roll-forming; thus the desired high-quality bending sections are achieved through a combination of theory and practice. This study mainly addresses the velocity of the rolls for sheets that have angle sides, and the spring-back of SGARC 440 alloy sheets in the roll forming process, where we use DEFORM to simulate the sheet.

scholarly journals A Method for Rapid Prediction of Edge Defects in Cold Roll Forming Process

Mathematics ◽  
2021 ◽  
Vol 9 (16) ◽  
pp. 1902
Author(s):  
Zhijuan Meng ◽  
Yanan Fang ◽  
Lidong Ma
Keyword(s):  
Longitudinal Strain ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Yield Strain ◽  
Cold Roll ◽  
Rapid Prediction ◽  
Edge Defects ◽  
The Mean ◽  
Roll Forming Process

In order to implement rapid prediction of edge defects in the cold roll forming process, a new analytical method based on the mean longitudinal strain of the racks is presented. A cubic spline curve with the parameters of the cumulative chord length is applied to fit the corresponding points and center points of different passes, and fitting curves are obtained. As the cold roll forming is micro-tension forming, the tensions between racks are ignored. Then the mean longitudinal strains between racks are obtained. By comparing the mean longitudinal strain between racks and the yield strain of the material, we can judge whether there are defects at the edges. Finally, the reasonableness of this method is illustrated and validated by an example. With this method, the roll forming effect can be quickly predicted, and the position where a greater longitudinal strain occurred can be determined. In order to prevent the defects, the deformation angles need to be modified when the result is beyond the yield strain. To further prove the correctness of the theory, the results of the analytical method are compared with the ones of the non-linear finite element software ABAQUS. The analytical results have the same trend as the finite element results. This method can provide useful guidance to the actual design process.

Validation of a FEM Model for the Simulation of the Cold Roll Forming Process

2015 ◽  
Vol 651-653 ◽  
pp. 219-224 ◽  
Author(s):  
Antonio Formisano ◽  
F. Capece Minutolo ◽  
Antonio Caraviello ◽  
Luigi Carrino ◽  
Massimo Durante ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Technological Process ◽  
Cross Section ◽  
Circular Cross Section ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Fem Model ◽  
Cold Roll ◽  
Roll Forming Process

Cold roll forming is a process for plastic deformation, which allows realizing profiles, with a defined section and established length, from the plastic deformation of a metal sheet. The sheet is induced to cross several stands of rolls, arranged along the same axis of advancing. The rolls induce plastic deformation in the sheet and then lead it to the desired geometric configuration. In order to control the geometric parameters of the plate during the profiling, it was created a FEM model to simulate the final stage of the technological process, developed by an industrial production line of a company located in Naples (Italy), that sells tubes with several cross sections. In this phase, the semi-finished product, having a circular cross section, is forced to cross through four stands of rolls. In this way, it changes the geometric condition of the cross section from circular to square. The model was carried out using a non-linear calculation code, which allows analyzing the parameters of interest in the different process steps. The results, obtained numerically, were compared with the experimental ones through the measurement of five specimens, obtained directly from technological process. The values of percentage deviation, regarding the external dimension and the thickness, for each step of advancement, do not exceed the 3% of error. Then, the analysis results denote the capability to simulate the cold roll forming process using finite element method.

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