Prototyping of Straight Section Components Using Incremental Shape Rolling

Flexible Roll Forming (FRF) allows the forming of components with a variable cross-section along the length of the component. However, the process has only limited application in the automotive industry due to wrinkling in the flange which currently prevents the forming of high strength steels and limits the part shape complexity. This paper presents a new forming technology, Incremental Shape Rolling (ISR), where a pre-cut blank is clamped between two dies and then a single forming roll is used to incrementally form the material to the desired shape. The new process is similar to some Incremental Sheet Forming (ISF) approaches but with the difference that Incremental Shape Rolling (ISR) allows the manufacture of longitudinal components from high strength metal sheets. In this work, a numerical model of the ISR of a straight section is developed. Experimental prototyping trials are performed and are used to validate the numerical model which is then applied to analyse the new forming process. The results show that in ISR, tensile residual strains are developed in the flange. Flange wrinkling is observed and directly linked to the number of forming passes that are used in the process.

Modeling of Microstructure Evolution during Deformation Processes by Cellular Automata—Boundary Conditions and Space Reorganization Aspects

Cellular automata (CA) are efficient and effective numerical tools for modeling various phenomena and processes, e.g., microstructure evolution in plastic working processes. In many cases, the analysis of phenomena can be carried out only in a limited space and on representative volume. This limitation determines the geometry of CA space hence boundary conditions are very important issues in modeling. The paper discusses different boundary conditions that can be applied to modeling. Taking into account the transformation of the modeling space, the model should allow the selection of boundary conditions. The modeling of certain phenomena and processes is directly related to changes in the geometry of a representative volume and therefore may require changes or reorganization of the modeled CA space. Four reorganization options are presented: halving, cutting and bonding, doubling, and straightening. A choice of boundary conditions may depend on particular space reorganization as used for the modeling of microstructure evolution. A set of decision rules for selecting space reorganization options taking into account the changes of CA shape and sizes is also presented. The modeling of flat and shape rolling processes utilizing some of the described techniques is shown.

Thermal Behavior of a Rod during Hot Shape Rolling and Its Comparison with a Plate during Flat Rolling

The thermal behavior of a rod during the hot shape rolling process was investigated using the off-line hot rolling simulator and numerical simulation. Additionally, it was compared with a plate during the flat rolling process to understand the thermal behavior of the rod during the hot rolling process in more detail. The temperature of the rod and plate during the hot rolling process was measured at several points with thermocouples using the rolling simulator, and then the measured temperature of each region of a workpiece was analyzed with numerical simulation. During hot rolling process, the temperature distribution of the rod was very different from the plate. The temperature deviation of the rod with area was much higher than that of the plate. The variation in effective stress of the rod along the circumferential direction can induce the temperature difference with area of the rod, whereas the plate had a relatively lower temperature deviation with area due to the uniform effective stress on the surface area. The heat generation by plastic deformation during the forming process also increased the temperature deviation of the rod with area, whereas strain distribution of the plate during flat rolling contributed to the uniformity of temperature of the plate with area. The higher temperature deviation of the rod along the circumferential and radial directions during the shape rolling process can increase the possibility of occurrence in surface defects compared to the plate during flat rolling.