Experimental study of bowing defects in pre-notched channel section products in the cold roll forming process

Bidabadi, Behrooz Shirani; Naeini, Hassan Moslemi; Tafti, Roohollah Azizi; Barghikar, H.

doi:10.1007/s00170-016-8547-y

Cited by 27 publications

(5 citation statements)

References 28 publications

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“…The longer trajectory length indicates a greater stretch during the formation process and, hence, a larger theoretical value for edge elongation [23].…”

Section: Analysis Of Materials Edge Extensionmentioning

confidence: 99%

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Research on the Mechanism and Processability of Roll Forming

Kang,

Sun,

Zhang

et al. 2024

Materials

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Cold bending forming is a complex forming process, and its product quality is closely related to the forming process parameters. To mitigate issues such as bulging and waviness arising from the extension of the material at the edges during the forming process of thin-walled circular tubes, a comprehensive comparative analysis was conducted on four forming methods. This analysis determined that the combined bending method is the optimal forming technique for the equipment. For the impact of different parameters on the equivalent plastic strain distribution of the product and the force on the rollers, numerical simulations were carried out using the software COPRA (COPRA FEA RF 2023.1) after designing the pattern diagram based on the integrated bending method. The results showed that different processing speeds on the equivalent plastic strain distribution and work hardening of the plate have little effect. As the spacing between the upper and lower rollers increases, the equivalent plastic strain of the plate to a certain extent and the value of the moment of the rollers is significantly reduced. Analyzing the performance characteristics of high-strength steel materials from the aspects of the thickness strain and cross-sectional forming of the plate, this verifies the advantages of forming high-strength steel plates. The numerical simulation results of this study are in good agreement with actual production experimental results.

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“…The longer trajectory length indicates a greater stretch during the formation process and, hence, a larger theoretical value for edge elongation [23].…”

Section: Analysis Of Materials Edge Extensionmentioning

confidence: 99%

“…comparing trajectory equations for points along the edge can provide an estimate for edge elongation. The longer trajectory length indicates a greater stretch during the formation process and, hence, a larger theoretical value for edge elongation [23].…”

Section: Comparison Of the Geometric Deformation Of Different Forming...mentioning

confidence: 99%

Research on the Mechanism and Processability of Roll Forming

Kang,

Sun,

Zhang

et al. 2024

Materials

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“…However, due to the multiple forming steps, control of the products’ geometry is complicated. 2 The most common defects that happen in the roll forming process are buckling, wrapping, edges wrinkling, and springback. There is a significant amount of research on potential solutions to these defects, tested via experimental and numerical methods.…”

Section: Introductionmentioning

confidence: 99%

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Bidabadi

Naeini

Safdarian

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In spite of product quality increase in the cold roll forming process by previous practical researches for defects prevention, there are some ill-considered defects such as over-bending, which diminished the product quality in the open section products of this process. This defect which happens by superfluous bending of sheet in the forming stand not only lead to defective products, but also trigger other defects such as edge wrinkling. Since in an elaborate process such as cold roll forming, forming parameters play an active role in defect prevention, the effect of some important parameters is investigated on the over-bending defect and product bending angle by doing 68 experimental tests and numerical simulations in the present study. The list of parameters which are investigated includes bend angle increment, flange width, strip thickness, radius of bend, strength of the materials, and inter-distance between successive stands. In addition, the reason behind the effect of each parameter on the accuracy of the bending angle is laid out. Results show that over-bending defect can be compensated or even eliminated by decreasing the bending angle in each stand, a technique called bending angle increment. Increasing the number of forming stands from two to five causes the over-bending to decrease from 6° to 0°. With bending angle increment being the most impactful factor, bending radius, flange width, and strip thickness have a decreasing impact on over-bending. This study also brings forward a reverse relationship between the strength of the material and the intensity of over-bending. The inter-distance between successive stands was found to have the least effect on over-bending. Results highlight the importance of pre-form rolls at the beginning of the roll forming line. Without the usage of pre-form rolls, the folding of strips on a 60° angle, cannot be done in one stand.

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“…This work shows that the horizontal plane projection trajectory at the end of the standing edge follows a cubic curve, proposing an ideal distribution of the bending angles. Bidabadi et al have also studied this phenomenon, [2] [3] evaluating the longitudinal bending of roll forming in a symmetrical U-shaped cross section both experimentally and numerically. These results show that the most important parameter is the forming angle.…”

Section: Introductionmentioning

confidence: 99%

Research on Comparison of Simulation and Experiment in Warpage Defects in Roll Forming Process of the Cap-Shaped Part Using a Five-Boundary Condition Forming Angle Distribution Function

Wang¹,

Feng²,

Wang³

et al. 2021

Preprint

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Warpage is one of the main defects in multi-pass roll forming. It manifests as the horizontal deviation in the sheet flange part after forming, impacting the final quality of the sheet. In this manuscript, we focus on the cap-shaped part of a small section profile. Considering the lack of previous scientific guidance on the distribution of forming angles—angles that lead to warpage defects and other defects reducing the quality of these products—a five-boundary condition distribution function of forming angle is proposed. We propose a mechanism for warpage defects in roll bending of a cap-shaped part based on this five-boundary condition forming angle distribution function. Furthermore, we examine the effects of forming angle, sheet thickness, and material yield strength on the warpage defects by examining the designed fluctuation of the edge wave, ∆z, and the maximum deviation of the profile curves of the flange edge, z', to test this theory, roll bending experiments are compared to simulation.

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Experimental study of bowing defects in pre-notched channel section products in the cold roll forming process

Cited by 27 publications

References 28 publications

Research on the Mechanism and Processability of Roll Forming

Research on the Mechanism and Processability of Roll Forming

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Research on Comparison of Simulation and Experiment in Warpage Defects in Roll Forming Process of the Cap-Shaped Part Using a Five-Boundary Condition Forming Angle Distribution Function

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