Numerical analysis of the flexible roll forming of an automotive component from high strength steel

Roll forming is a highly useful and important forming technique for sheet metal. As an economic profile product, roll forming products are widely used in transportation, engineering machinery, and civil construction because of their uniform sections, high strength, and low energy consumption[1]. Roll forming is a rapid processing operation used for transforming flat sheets of material into useful profiled sections. However, a lot of components used in the automobile, railway cars, ship construction, and building industries have variable cross sections. Therefore, flexible roll forming was developed recently to produce variable cross section profiles.

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UHS Steel Formability in Flexible Roll Forming

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.410-411.661 ◽

2009 ◽

Vol 410-411 ◽

pp. 661-668 ◽

Cited By ~ 9

Author(s):

Kari Mäntyjärvi ◽

Marion Merklein ◽

Jussi A. Karjalainen

Keyword(s):

High Strength ◽

Experimental Tests ◽

Single Step ◽

Manufacturing Technology ◽

Roll Forming ◽

Bending Tests ◽

Air Bending ◽

Flexible Roll Forming ◽

The Poor ◽

Flexible Roll

Ultra-high-strength (UHS) steels are very interesting materials for many applications where high strength can be utilized to create lighter and more effective constructions. The poor formability of UHS steels, however, may limit the usefulness of these materials in many applications. In this work, some experiments using a flexible roll forming machine developed at the Chair of Manufacturing Technology (LFT), University of Erlangen-Nuremberg were carried out using 4mm-thick bainitic martensitic UHS steels (YS/TS 960/1000 and 1100/1250) and the outcomes have been analysed. Results of these experimental tests show that using roll forming it is possible to bend test materials to an angle of 90º without damages with an evidently smaller radius than in air bending. The radius obtained using roll forming can be as small as 40% of the value used in air bending. Tests also show that with the method used in these tests it is possible to make roll forming for the whole length of the plate. The tests proved that the NC-controlled single-step roll forming method has potential for manufacturing small batches of bend profiles; however, more development has to be carried out if the process is to be made suitable for industry.

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Track Simulation of Flexible Roll Forming Based on VC++ and OpenGL

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.457-458.304 ◽

2012 ◽

Vol 457-458 ◽

pp. 304-307

Author(s):

Wen Ting Sun ◽

Qiang Li ◽

Bo Qian

Keyword(s):

Rotation Angle ◽

High Strength ◽

Roll Forming ◽

Interpolation Algorithm ◽

Nc System ◽

Flexible Roll Forming ◽

Forming Technology ◽

Core Module ◽

Flexible Roll ◽

Track Simulation

How to manufacture high accuracy, complex section, high strength steel products is the current challenge of flexible roll forming technology. This article introduced opening NC system application in flexible roll forming, both in software and in hardware. As the core module of the software system, the interpolation module was discussed. The article mainly focused on how to establish track simulation module. According to the algorithm, we calculated the roller displacement and rotation angle using VC++. At last the simulation processes and results were presented, which prove the trace interpolation algorithm is correct and feasible.

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