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

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 470
Author(s):  
Mohanraj Murugesan ◽  
Muhammad Sajjad ◽  
Dong Won Jung
Keyword(s):  
Rolling Direction ◽  
Strip Thickness ◽  
Image Correlation ◽  
Roll Forming ◽  
Al Alloy ◽  
Spring Back ◽  
Cold Roll Forming ◽  
Time Step ◽  
Analytical Technique ◽  
Cold Roll

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.

scholarly journals Effect of Plastic Anisotropy and Process Parameters on the Final Geometry of U-shaped Product in Cold Roll Forming

2021 ◽  
Author(s):  
Amin Poursafar ◽  
Saeid Saberi ◽  
Rasoul Tarkesh ◽  
Meisam Vahabi ◽  
Javad Jafari Fesharaki
Keyword(s):  
Final Section ◽  
Plastic Anisotropy ◽  
Strip Thickness ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Factors Influencing ◽  
Cold Roll ◽  
Roll Forming Process

Abstract Since the cold roll forming process is currently used in the production of different sections, it is necessary for manufacturers to further improve the quality of these products. Therefore, it is essential to study various factors influencing the production of these products in detail and provide effective solutions to reduce the factors causing defects in such products. This paper investigates the effect of plastic anisotropy and various factors such as strip thickness, the inter distance between stands, web width, and angle increment on the longitudinal bowing and then compares the results with the practical experiments. Accordingly, a model considering the effect of these parameters on the longitudinal bowing of the final section is considered with the accuracy of 88%. The results show that strip thickness and the increment angle at each stand, and the web width have the most influence on the longitudinal bowing, while strip anisotropy and the inter distance has the least effect on bowing.

Cold Roll Forming Process and Die Design for Double-Gutter Frame of Drawer Slider

2014 ◽  
Vol 626 ◽  
pp. 205-210 ◽  
Author(s):  
Jinn Jong Sheu ◽  
Chia Cheng Hsieh ◽  
Cheng Hsien Yu
Keyword(s):  
Strain Distribution ◽  
Local Strain ◽  
Die Design ◽  
Roll Forming ◽  
Spring Back ◽  
Cold Roll Forming ◽  
Forming Process ◽  
End Point ◽  
Cold Roll ◽  
Roll Forming Process

In this paper, the main focus is to demonstrate a systematic method of designing the roll flower and corresponding dies for a double-gutter frame applied to the drawer slider. The blank development method was proposed to calculate the width of blank for bending with small radii. The cold roll forming process design was based on the maximum longitudinal strain minimization and the interference of rolls with the double-gutter geometry of product profile. Extra pre-bending was designed to avoid the occurrence of blank collision during forming process. The FEM method was adopted to evaluate the process and die designs. Due to the geometry complexity of the product, strain distribution is uneven which results in more spring back and stress concentration. A geometry setting design was proposed to create local strain redistribution and smooth strain distribution of entire section profile after final forming step. Using geometry setting die design, the spring back at the end point and the gutter areas of final product section are 0.07 mm and 0.1 mm, respectively. Without the geometry setting die design, the spring back at the end point and the gutter areas of final product section are 0.11 mm and 0.15 mm, respectively. The simulation results demonstrate the proposed methods are able to improve the accuracy of cold roll forming products.

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.

Continuous Roll Forming Simulation Using Arbitrary Lagrangian Eulerian Formalism

2011 ◽  
Vol 473 ◽  
pp. 564-571 ◽  
Author(s):  
Romain Boman ◽  
Jean Philippe Ponthot
Keyword(s):  
Numerical Simulation ◽  
Rolling Direction ◽  
Initial Guess ◽  
Roll Forming ◽  
Arbitrary Lagrangian Eulerian ◽  
The Finite Element Method ◽  
Forming Simulation ◽  
Element Size ◽  
Cold Roll ◽  
Classical Lagrangian

Due to the length of the mill, accurate modelling of stationary solution of continuous cold roll forming by the finite element method using the classical Lagrangian formulation usually requires a very large mesh leading to huge CPU times. In order to model industrial forming lines including many tools in a reasonable time, the sheet has to be shortened or the element size has to be increased leading to inaccurate results. On top of this, applying loads and boundary conditions on this smaller sheet is usually more difficult than in the continuous case. Moreover, transient dynamic vibrations, which are unnecessarily computed, may appear when the sheet hits each tool, decreasing the convergence rate of the numerical simulation. Beside this classical Lagrangian approach, an alternative method is given by the Arbitrary Lagrangian Eulerian (ALE) formalism which consists in decoupling the motion of the material and the mesh. Starting from an initial guess of the sheet geometry between the rolls, the numerical simulation is performed until the stationary state is reached with a mesh, the nodes of which are fixed in the rolling direction but are free to move on perpendicular plane, following the geometrical boundary of the sheet. The whole forming line can then be modelled using a limited number of brick and contact elements because the mesh is only refined near the tools where bending and contact occur. In this paper, ALE results are compared to previous Lagrangian simulations and experimental measurement on a U-channel, including springback. Advantages of the ALE method are finally demonstrated by the simulation of a tubular rocker panel on a 16-stands forming mill.

scholarly journals Fundamental Research on the Cold-Roll Forming of Metal Strips

1964 ◽  
Vol 7 (28) ◽  
pp. 827-834 ◽  
Author(s):  
Moriji MASUDA ◽  
Tadao MUROTA ◽  
Takashi JIMMA ◽  
Toshitaka TAMANO ◽  
Toshiyuki AMAGAI
Keyword(s):  
Roll Forming ◽  
Cold Roll Forming ◽  
Cold Roll ◽  
Fundamental Research

Computer aided simulation of cold roll forming — a computer program for simple section profiles

1996 ◽  
Vol 59 (1-2) ◽  
pp. 41-48 ◽  
Author(s):  
Nitin Duggal ◽  
Mustafa A. Ahmetoglu ◽  
Gary L. Kinzel ◽  
Taylan Altan
Keyword(s):  
Computer Program ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Cold Roll ◽  
Computer Aided

Effect of forming parameters on edge wrinkling in cold roll forming of wide profiles

2018 ◽  
Vol 101 (1-4) ◽  
pp. 181-194 ◽  
Author(s):  
H. Mohammdi Najafabadi ◽  
H. Moslemi Naeini ◽  
R. Safdarian ◽  
M. M. Kasaei ◽  
D. Akbari ◽  
...  
Keyword(s):  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Parameters ◽  
Cold Roll
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