Effect of forming parameters on edge wrinkling in cold roll forming of wide profiles

Abstract

The cold roll forming is a continuous metal forming process to produce a large variety of profiles. A major product of the cold roll forming is wide profiles whose application is expanding in the construction of houses, bridges, airports, sports arenas, etc. The edge wrinkling is one of the common defects in the cold roll forming of the wide profiles. The edge wrinkling leads to several problems, such as decrease of dimensional tolerances, abrasion of forming rolls due to contact with the wrinkled edge, non-uniform distribution of forming through the production line, and unsuitable energy consumption. In this paper, the mechanics of edge wrinkling in the cold roll forming of the wide profile is investigated, and the effect of the most important forming parameters on this defect is determined by means of experimental tests and numerical simulations. This research work is performed in St12 steel sheets, and the results show that wrinkling increases with the increase of the outer flange width and inner flange width, while it decreases with the increase of the strip thickness and the distance between the roll stands. Results also show that web width does not have a noticeable effect on the wrinkling.