A New Engineering Technique in Roller Design to Prevent Thinning of Sheet in Roll Forming Process

Abstract

These days sheet metal forming is a widely used in different industrial fields with large production volumes. Formability of metal sheets is limited by localized necking and plastic instability. In sheet metal forming processes like drawing and stamping the main challenge is thinning of the metal sheet in some regions. To reduce thinning of the sheet product, roll forming has been suggested instead of stamping process. Thinning strain can cause necking, tearing or wrinkling which are failure of the metal sheet. In this study a new engineering technique is proposed in order to prevent thinning of the steel galvanized hot coil commercial (SGHC) in roll forming process. An explicit finite element code, ABAQUS software, was used to simulate the roll forming process. The results show that the proposed technique has an important effect on thinning of the sheet and can reduce it significantly. Investigation on the second and third and fourth rollers show the effect of modified roller dimension as on reducing the thickness. These reductions in second, third and fourth rollers are from 4 percent to 0.5 percent, 2.8 to 1.4 percent and from 1.4 to 0.7 percent respectively. The reasons of the new techniques effect were also discussed.