Estimation of Cold Roll Forming Characteristics of Wrought Magnesium Alloy with Tension-Compression Asymmetry

In recent years, the movement for banning the sale of gasoline cars and diesel vehicles, especially in Europe, and allowing only electric passenger cars has been accelerated. For examples, Germany’s federal council, the Bundesrat, has passed a resolution calling for a ban on combustion engine cars by 2030. If the ban were to go through, German citizens would only be permitted to purchase electric or hydrogen-fueled cars. In Norway, until 2025 there is a movement for legislation prohibiting the registration of new gasoline passenger cars and diesel cars. Beginning in 2025 in the Netherlands, a bill prohibiting the sale of new cars gasoline and diesel vehicles was submitted to Congress. Under the circumstances, the demand for light-weight products for automotive industries has increased due to global trends in environmental preservation. Although demands for magnesium has risen dramatically, production of magnesium alloy sheet still remains at a very low level. This study seeks to establish a guideline for roll design in the roll forming of wrought magnesium alloys to extend practical use of roll-formed products of wrought magnesium alloys. A three-dimensional elasto-plastic analysis by the finite-element method has been conducted to express exact roll-forming behavior of wrought magnesium alloys that have different stress-strain curves in tension and compression. Simple V-sections were formed by a tandem six-stand roll forming machine to demonstrate the effectiveness of the simulation methods with different stress-strain curves in the case of tension and compression. Also, spring-back analysis has been performed to investigate the exact cold roll-forming phenomenon for wrought magnesium alloy sheets.