abeyrathna-numericalanalysis-2016.pdf (1.62 MB)
Numerical analysis of the flexible roll forming of an automotive component from high strength steel
conference contribution
posted on 2016-01-01, 00:00 authored by Buddhika Abeyrathna, A Abvabi, Bernard RolfeBernard Rolfe, R Taube, Matthias WeissMatthias WeissConventional roll forming is limited to components with uniform cross-section; the recently developed flexible roll forming (FRF) process can be used to form components which vary in both width and depth. It has been suggested that this process can be used to manufacture automotive components from Ultra High Strength Steel (UHSS) which has limited tensile elongation. In the flexible roll forming process, the pre-cut blank is fed through a set of rolls; some rolls are computer-numerically controlled (CNC) to follow the 3D contours of the part and hence parts with a variable cross-section can be produced. This paper introduces a new flexible roll forming technique which can be used to form a complex shape with the minimum tooling requirements. In this method, the pre-cut blank is held between two dies and the whole system moves back and forth past CNC forming rolls. The forming roll changes its angle and position in each pass to incrementally form the part. In this work, the process is simulated using the commercial software package Copra FEA. The distribution of total strain and final part quality are investigated as well as related shape defects observed in the process. Different tooling concepts are used to improve the strain distribution and hence the part quality.
History
Event
Materials Science and Engineering. IOP Conference Series (2016 : Linz, Austria)Volume
159Issue
1Pagination
1 - 9Publisher
IOP PublishingLocation
Linz, AustriaPlace of publication
Bristol, Eng.Publisher DOI
Start date
2016-06-12End date
2016-06-15ISSN
1757-8981eISSN
1757-899XLanguage
engPublication classification
E1 Full written paper - refereedCopyright notice
2016, The AuthorsTitle of proceedings
IDDRG 2016 : Challenges in Forming High-Strength Sheets : Proceedings of the IOP Conference Series Materials Science and EngineeringUsage metrics
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