Investigation of High Strength Steel for Automotive Roll-Forming Parts

2011 ◽  
Vol 189-193 ◽  
pp. 3001-3006 ◽  
Author(s):  
Pei Jie Yan ◽  
Jing Tao Han ◽  
Zheng Yi Jiang ◽  
Hei Jie Li ◽  
Li Xian Liu
Keyword(s):  
High Strength Steel ◽  
Human Life ◽  
High Strength ◽  
Structure Design ◽  
Roll Forming ◽  
Advanced Manufacturing ◽  
Forming Process ◽  
Ultra High Strength Steel ◽  
Automotive Parts ◽  
Roll Forming Process

In recent years, the number of automobiles has been steadily increasing, which has significantly impacted on the society and human life, and led to many social problems such as fuel crisis, environment pollution. Therefore, lightweight designing becomes a focused issue. Lightweight materials application, optimized structure design and advanced manufacturing process are the main ways to achieve the lightweight. However, low plasticity and ductility of high strength steel constrain the application of high strength steel. In this paper, the basic principle of roll forming for automotive parts is investigated, and it is innovatively applied in the hot roll forming process of the ultra high strength steel.

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.

Hot Spline Forming of Ultra-High Strength Steel Gear Drum Using Resistance Heating

2014 ◽  
Vol 622-623 ◽  
pp. 201-206 ◽  
Author(s):  
Kenichiro Mori ◽  
Tomoyoshi Maeno ◽  
Shohei Nakamoto
Keyword(s):  
Deep Drawing ◽  
High Strength Steel ◽  
Side Wall ◽  
High Strength ◽  
Axial Direction ◽  
Resistance Heating ◽  
Sectional Area ◽  
Forming Process ◽  
Cross Sectional ◽  
Ultra High Strength Steel

A hot spline forming process of die-quenched gear drums using resistance heating of a side wall of a cup formed by cold deep drawing and ironing was developed. The side wall having uniform cross-sectional area is resistance-heated by passage of the current in the axial direction, the heated side wall of the drawn cup is ironed and is finally die-quenched. The gear drum was successfully formed and the hardness was between 400 and 500 HV. Not only the formability was improved but also the formed dram was hardly oxidised because of rapid resistance heating.

Study on Properties of High Strength Steel during Warm Roll Forming

2012 ◽  
Vol 472-475 ◽  
pp. 2783-2787 ◽  
Author(s):  
Pei Jie Yan ◽  
Jing Tao Han ◽  
Zheng Yi Jiang ◽  
Hei Jie Li ◽  
Dan Yang Li
Keyword(s):  
High Strength Steel ◽  
High Strength ◽  
New Method ◽  
Experimental Result ◽  
Roll Forming ◽  
Production Cycle ◽  
Complex Process ◽  
Ultra High Strength Steel ◽  
Deformation Complex ◽  
Good Agreement

Roll forming is a 3D deformation complex process. Stiffness of stands and strength of shafts are the preconditions for the production of precision products. However, the existing roll forming equipment cannot meet the requirements of the production for high strength steel or ultra high strength steel. In order to solve the forming problem of high strength steel or ultra high strength steel, it needs to redesign a set of roll forming equipment. The redesign of roll forming equipment not only makes the production cycle too long, but also results in a high cost. So it is not suitable for the production of forming products. In this paper, based on the existing roll forming equipment a new method of roll forming operation is proposed to optimize the production of U shaped products. The influences of the new method on the roll forming products such as mechanical properties, microstructures and surface qualities, have also been discussed, Based on the new warm roll forming operation, numerical simulation has also been carried out. The simulation result of geometry is in good agreement with experimental result.

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