Residual Stress Around Cut End of Hat Steel Channel by Roll Forming

Saffe, Siti Nadiah binti Mohd; Nagamachi, Takuo; Ona, Hiroshi

doi:10.1016/j.proeng.2014.09.157

Cited by 13 publications

(11 citation statements)

References 4 publications

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“…Therefore, from the simulation assisted by the SSEA, profiles with longer stationary zones can be obtained which is useful in analysis of springback and cut-off deformation. [39,40] The cross-section measurement of the conventional simulation confirms the results of the simulation using SSEA. Measurements and simulations yield similar values for angle A. Deviations are in the range of tolerances according to DIN EN 10162.…”

Section: Experimental Validation and Numerical Verification Of The Sseasupporting

confidence: 58%

“…An isotropic power‐law hardening rule is described as

σ_{f} = K \times {(ϵ_{p})}^{n}

, where σ f is the flow stress, K is the strength coefficient, ϵ p is the plastic strain, and n is the strain hardening coefficient. Non‐linear kinematic hardening is neglected as no plastic unbending occurs during the forming . In simulations, the contact is established by a node‐to‐segment contact algorithm .…”

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

“…The springback values vary slightly for the conventional simulation as there exists a slight variation in the state variables even in the stationary zone. Therefore, from the simulation assisted by the SSEA, profiles with longer stationary zones can be obtained which is useful in analysis of springback and cut‐off deformation …”

Section: Experimental Validation and Numerical Verification Of The Sseamentioning

confidence: 99%

“…Non-linear kinematic hardening is neglected as no plastic unbending occurs during the forming. [20,39] In simulations, the contact is established by a node-to-segment contact algorithm. [25] Figure 8 depicts the boundary conditions.…”

Section: Basic Numerical Modelmentioning

confidence: 99%

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FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties

Mahajan

Abrass

Groche

2018

steel research int.

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Roll forming is a continuous, steady state process where state variables remain unchanged over the process time with respect to a fixed position. The design of roll forming is a complex and iterative process which mainly depends on the experience of designers. In industry, the finite element analysis (FEA) is commonly used to design rolls and to predict important process variables such as longitudinal peak strains and springback. However, the FEA is attributed with a high computational cost. The approach described in this paper aims at the reduction of the computational cost with the aid of steady state properties evolved in roll forming. To exploit the steady state properties, the steady state extrapolation algorithm (SSEA) is used in conjunction with conventional FE simulations. A complex profile requiring 10 roll forming stations is considered for the validation of the simulations. Experimental measurements confirm the results from conventional simulation as well as the simulation assisted by the SSEA. Springback behavior predicted by the simulation using SSEA is also verified successfully. With the help of the SSEA, the total computational time for the FE analysis of the complex profile is reduced by 54.7%.

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Section: Experimental Validation and Numerical Verification Of The Sseasupporting

confidence: 58%

“…An isotropic power‐law hardening rule is described as

σ_{f} = K \times {(ϵ_{p})}^{n}

Section: Experimental and Numerical Investigationsmentioning

confidence: 99%

Section: Experimental Validation and Numerical Verification Of The Sseamentioning

confidence: 99%

Section: Basic Numerical Modelmentioning

confidence: 99%

See 2 more Smart Citations

FE Simulation of Roll Forming of a Complex Profile with the Aid of Steady State Properties

Mahajan

Abrass

Groche

2018

steel research int.

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“…As a result, end flare can differ for every profile geometry and the deformation can change after each forming step. [24,28]…”

Section: Residual Stresses In Roll Formingmentioning

confidence: 99%

The origin of end flare in roll formed profiles

Moneke

Groche

2021

Int J Mater Form

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Roll forming is a continuous manufacturing process designed for large batch sizes. In order to economically produce roll formed parts with smaller batch sizes, the process setup times have to be reduced. During the setup, profile defects and especially the deformation caused by the release of the process-inherent residual stresses, also known as end flare, have to be counteracted. However, the knowledge regarding the creation of residual stresses is limited and the ability to reduce end flare usually depends on the experience of the process designer and the machine operator, which makes the setup time-consuming and cost-intensive. Therefore, in this paper the creation of end flare during the roll forming process is investigated in depth. As a result of this study explanation models for U-, C- and Hat-profiles, which link the creation of residual stresses to the local deformation during the forming process, are developed. Knowing how changes in the forming curve affect the creation of end flare allows to use a knowledge-based approach during the design and setup process, thereby reducing time and costs.

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