Abstract
Cold roll forming is suitable for sheet metal processing and can provide a new method for the production and processing of anti-collision beams for commercial vehicles. In order to accurately control the edge wave defects of the parts in the roll forming process, we used the professional roll design software COPRA to design the roll pattern and used the professional finite element analysis software ABAQUS to establish a three-dimensional finite element analysis model of the “b”-shaped cross-section. We analyzed the factors affecting the edge wave by controlling different process parameters (the thickness of the sheet, the height of the flange, and the forming speed), and the best process parameter combination was determined. The results showed that the thickness of the sheet, the height of the flange, and the forming speed all had an effect on the edge wave defects of the “b”-shaped cross-section. The influence of sheet thickness was the greatest, followed by flange height and then forming speed. The final selected parameter combination was a sheet thickness of 3 mm, a flange height of 100 mm, and a forming speed of 150 mm/s. This work provides a theoretical basis for actual production.
Highlights
Roll forming is a processing method in which metal sheets sequentially pass through multiple forming rolls to form the required product geometric cross-section profiles
One of the main problems is that the product produces edge wave defects, which often leads to undesirable product shapes and affects welding performance
Cao et al used COPRA software to analyze the roll forming process of Metals 2021, 11, x FOR PEER REVIEW the asymmetric “8” tube, and the results showed that the defects were m2aoinf l1y3 caused by uneven force on the top of the section [4]
Summary
Roll forming is a processing method in which metal sheets sequentially pass through multiple forming rolls to form the required product geometric cross-section profiles. The roll forming process can produce high-quality cold-formed steel, shorten the production cycle, and improve the production efficiency. This processing method is widely used in many fields, such as auto parts, ships, oil and gas pipelines, the power electronics industry, and machinery manufacturing. The use of roll forming technology in the manufacturing process and the use of high-strength steel as material have become the two main ways to achieve lightweight cars and increase crash safety performance [1]. The main factors that affect the edge wave defects of sheet roll forming are the finite element calculation me2t.hModa,tferircitaiol nPcroepfefirctiieenst,asnhedetEtdhgiceknWesasv,eflsange height, and forming speed. WDDiiaffvffeeesrreeannnttdrrEoovllllalaaunnaggtilloeenss Mwwiielltllhccoaaduusssee ddiiffffeerreenntt ddeeffoorrmmaattiioonnss ooff tthhee sshheeeett iinn ddiiffffeerreeDnnutt rppinaagrrttstshiiennrttohhlleeffofoorrmrmminiinngggpddroiirrceeeccsttsii,ootnnh..eTTshheeeeetddmggoeesvs eoosffattlhhoeengsshhiteeseefttowwrmiilllilnbbgeedeeillrooennctggioaatntee,ddasddsuuheeowttoon tthhinee Fiinnigccrrueeraaess2ee.iinDn ihhffeeeiigrgehhnttt. There are two traditional processing methods for “日”-shaped cross-sections
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