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Numerical analysis of the flexible roll forming of an automotive component from high strength steel

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conference contribution
posted on 2016-01-01, 00:00 authored by Buddhika Abeyrathna, A Abvabi, Bernard RolfeBernard Rolfe, R Taube, Matthias WeissMatthias Weiss
Conventional 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

159

Issue

1

Pagination

1 - 9

Publisher

IOP Publishing

Location

Linz, Austria

Place of publication

Bristol, Eng.

Start date

2016-06-12

End date

2016-06-15

ISSN

1757-8981

eISSN

1757-899X

Language

eng

Publication classification

E1 Full written paper - refereed

Copyright notice

2016, The Authors

Title of proceedings

IDDRG 2016 : Challenges in Forming High-Strength Sheets : Proceedings of the IOP Conference Series Materials Science and Engineering