Research on roll forming process and springback based on five-boundary condition forming angle distribution function

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In the present study, a five-boundary conditional distribution function of the forming angle is proposed. The stress, strain, and springback of a sheet in roll-forming process under three different angle distribution functions are studied. Furthermore, effects of forming angle increment, sheet thickness, and material yield strength on stress, strain distribution, and springback of sheet during roll forming are studied under optimized forming angle. The results demonstrate that stress, strain, and springback of each pass based on increment of forming angle under five-boundary condition during roll forming are less than those achieved by other forming angle distribution methods. The stress and strain in the bending zone increase with increase in the sheet thickness. After roll forming, the springback angle decreases with the increase of sheet thickness, increases with the increase of forming angle and material yield strength. However, springback angle can be effectively reduced by increasing the number of passes or correction rolls.