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

Bidabadi, Behrooz Shirani; Naeini, Hassan Moslemi; Safdarian, R.; Barghikar, H.

doi:10.1177/09544054221076628

Cited by 7 publications

(4 citation statements)

References 36 publications

(42 reference statements)

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“…Gao et al [11] designed a set of roll position automatic adjustment system that can predict roll parameters by using PCA-BP algorithm to train roll parameter prediction model, so as to predict roll parameters of newly developed square tube cold roll forming distribution. Bidabadi et al [12] studied the in uence of bend angle increment, ange width, strip thickness, bending radius and material strength on over-bending defect ground by combining multiple groups of test and numerical simulation. Therefore, the appropriate cold roll forming process is also an important guarantee for the precise forming of circular tubes of different speci cations.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Cao

Wang

Ruan

et al. 2023

Int J Adv Manuf Technol

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In view of the problems of poor exibility of conventional roll forming of circular tubes, the UDF (USTB-Durable F) exible roll forming method was used to model and simulate ve kinds of thin-walled circular tubes with different thicknesses and the same outer diameter, so as to verify the applicability of UDF exible roll forming method. In order to realize the commonality of UDF rolls, according to the roll positions of seven kinds of thin-walled circular tubes with different outer diameters and thicknesses within the speci cation range, mathematical models between tube speci cations and corresponding roll position parameters were established. Combined with the actual parameters of the thin-walled circular tube roll forming unit, the UDF forming process suitable for the exible forming of thin-walled circular tubes was obtained and compared with the conventional process by nite element simulation. Results show that the edge molding quality of the UDF process is better than that of the conventional process, and the amount of springback is less and the accuracy of the outer diameter of the section is high. The establishment of the roll position mathematical model and the special process parameters of the UDF exible roll forming method provides a reference for the development of exible production of roll forming of circular tubes.

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Section: Introductionmentioning

confidence: 99%

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Cao

Wang

Ruan

et al. 2023

Int J Adv Manuf Technol

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“…[1][2][3][4] With the continuous development and maturity of finite element simulation technology, more and more scholars today were using finite element analysis to study the deformation process of sheets. 5,6 Finite element simulation also plays an important role in the study of part springback. Sun et al 7 found that the hot forming of high-strength steel significantly reduced springback by about 62% compared to cold forming through the finite element model developed and also found that rapid forming was beneficial in reducing springback.…”

Section: Introductionmentioning

confidence: 99%

Influence of local features on twist springback of high-strength steel long channels

Li,

Wang,

Pang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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With the wide use of high-strength steel (HSS) in structural body parts, the twist springback of high-strength steel parts has received extensive attention. Unlike automotive panels, structural body parts are arranged with many local features to meet functional requirements. The aim of this study is to investigate the influence of local features on twist springback to optimize the design of local features to reduce twist springback. In this paper, a typical long channel part (A-pillar upper inner plate) is taken as the object of study. A suitable location division method for this type of part is proposed to investigate the changes in twist springback and cross-sectional stresses in the part before and after the addition of local features at different locations through finite element simulations. The results show that the local features affect the stiffness and stress distribution of the parts and significantly affect the twist springback of the parts. Finally, the research results guided the optimization of the local feature design of an A-pillar upper inner plate, resulting in a remarkable 37% and 61% decrease in twist springback at the left and right ends of the optimized part, respectively. In addition, stamping molds were developed for optimized parts, and experiments were carried out to verify the effectiveness of the law and the reliability of the finite element model.

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“…Over-bending in the open section of the panels may also diminish their overall quality and trigger other defects such as edge wrinkling. 5 Other manufacturing solutions based on conventional forming of grooves with punch and die sets 6,7 are limited by the time and cost to fabricate the tools and because these are dependent on the geometry of the panels. Despite electromagnetic forming allows one element of the tool set (usually the punch) to be replaced by a coil, this process variant is limited to highly conductive materials, to small size panels and cannot avoid the groove geometry dependence of the dies.…”

Section: Introductionmentioning

confidence: 99%

“…Over-bending in the open section of the panels may also diminish their overall quality and trigger other defects such as edge wrinkling. 5…”

Section: Introductionmentioning

confidence: 99%

Groove stiffening of sheets by single point incremental forming

Cristino

Pragana

Bragança

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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This paper investigates the applicability of single point incremental forming to fabricate stiffening grooves in thin metallic panels. The work combines experimentation, finite element and analytical modelling to determine the required forces and the maximum allowable groove depths that can be produced without tearing. The analytical modelling is based on a framework that was previously developed by the authors and combines in-plane membrane stretching and fracture forming limits. Comparison of the results obtained by the analytical framework against experimental and finite element data proves its effectiveness to replicate the deformation mechanics of groove stiffening by single point incremental forming. Results also prove that groove stiffening by single point incremental forming is an easy and effective alternative to conventional reinforcement of thin metallic panels by welding or fastening of stringers.

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

Cited by 7 publications

References 36 publications

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Influence of local features on twist springback of high-strength steel long channels

Groove stiffening of sheets by single point incremental forming

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