The influence of residual stress on a roll forming process

2015 ◽  
Vol 101-102 ◽  
pp. 124-136 ◽  
Author(s):  
A. Abvabi ◽  
B. Rolfe ◽  
P.D. Hodgson ◽  
M. Weiss
Keyword(s):  
Residual Stress ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Development of an Inverse Routine to Predict Residual Stresses in the Material Based on a Bending Test

2013 ◽  
Vol 554-557 ◽  
pp. 949-956 ◽  
Author(s):  
Akbar Abvabi ◽  
Bernard Rolfe ◽  
Peter Hodgson ◽  
Matthias Weiss
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Test Data ◽  
Bending Test ◽  
Roll Forming ◽  
Stress Profile ◽  
Forming Process ◽  
Residual Stress Profile ◽  
Difficult Time ◽  
Roll Forming Process

Bending with unloading and reverse bending are the dominant material deformations in roll forming and hence property data derived from bend tests could be more relevant than tensile test data for numerical simulation of the roll forming process. Recent investigations have shown that residual stresses affect the material behaviour close to the yield in a bending test. So, Residual stress introduced during prior steel processing may affect the roll forming process and therefore needs to be included in roll forming simulations to achieve improved model accuracy. Measuring the residual stress profile experimentally is expensive, difficult, time consuming and has limited accuracy. Analytical models are available that allow the determination of residual stress. However, for this detailed information about the pre-processing conditions is required; this information is generally not available for roll forming materials. The main goal of this study is to develop an inverse routine that generates a residual stress profile through the thickness of the material based on pure bend test data.

scholarly journals Investigations of the through-thickness residual stress distribution during the partial heating roll forming process of square and rectangular hollow steel sections

2021 ◽  
Author(s):  
Zelalem Abathun Mehari ◽  
Jingtao Han
Keyword(s):  
Residual Stress ◽  
Experimental Studies ◽  
Roll Forming ◽  
Experimental Investigations ◽  
Small Scale ◽  
Stress Distributions ◽  
Forming Process ◽  
Partial Heating ◽  
Steel Sections ◽  
Roll Forming Process

With the growing demand for rectangular and square hollow steel sections in the last few decades, the cold roll forming process has become a widely acknowledged hollow sections manufacturing method; however, residual stress generated during the roll forming process is one of the primary concerns on roll-formed products. In this regard, several researchers have conducted numerical and experimental investigations of residual stress distributions on roll-formed steel sections. However, most of the studies found in the literature have been confined to the measurement of residual surface stresses. On the other hand, experimental studies conducted on fatigue and load-carrying capacity of hollow structural steels have shown that there is indeed a simple relation between the through-thickness residual stress distributions and mechanical properties of structures. Thus, this paper employed a proper numerical modelling procedure using LS-DYNA’s finite element code to explore through-thickness residual stress distributions generated during the roll forming process of rectangular and square hollow steel sections from different material grades. Moreover, a small-scale parametric study was conducted to explore the effects of the partial heating roll forming method on through-the-thickness residual stress distributions to satisfy the growing demand for residual stress-free roll-formed products.

Computerized Numerical Simulation of Roll-Forming Process

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 239-242 ◽  
Author(s):  
Manabu Kiuchi ◽  
Kenji Abe ◽  
Ryu Onodera
Keyword(s):  
Numerical Simulation ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Quadrilateral Shape Rib Forming by Roll Forming Process

2018 ◽  
Vol 878 ◽  
pp. 296-301
Author(s):  
Dong Won Jung
Keyword(s):  
Automotive Industry ◽  
High Strength Steel ◽  
Numerical Study ◽  
Thickness Distribution ◽  
High Strength ◽  
Metal Sheet ◽  
Product Performance ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

The roll forming is one of the simplest manufacturing processes for meeting the continued needs of various industries. The roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for making structural components. In order to reduce the thinning of the sheet product, traditionally the roll forming has been suggested instead of the stamping process. The increased product performance, higher quality, and the lowest cost with other advantages have made roll forming processes suitable to form any shapes in the sheets. In this numerical study, a Finite Element Method is applied to estimate the stress, strain and the thickness distribution in the metal sheet with quadrilateral shape, ribs formed by the 11 steps roll forming processes using a validated model. The metal sheet of size 1,000 × 662 × 1.6 mm taken from SGHS steel was used to form the quadrilateral shape ribs on it by the roll forming process. The simulation results of the 11 step roll forming show that the stress distribution was almost uniform and the strain distribution was concentrated on the ribs. The maximum thinning strain was observed in the order of 15.5 % in the middle rib region possibly due to the least degree of freedom of the material.

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