Abstract
Process parameters crucially influence product quality in complex roll-forming process. Improper setting of process parameters can cause springback and peak longitudinal strain, resulting in product defects. In the present study, the main process parameters considered are forming angle and sheet thickness. The forming angle for each pass of forming is allocated reasonably by applying a five-boundary condition, which forms an angle distribution function, to further study the effects of sheet thickness and material properties on the peak longitudinal strain and springback. Moreover, transverse strain in the bending zone was studied based on the microstructure of the sheet used herein. The results of finite element simulation and experiments demonstrate that the peak longitudinal strain increases with increase in the forming angle. The peak longitudinal strain decreases with the sheet thickness increases, while the transverse strain increases with the sheet thickness increases. The springback decreases with the increase of sheet thickness under the condition of a certain roll radius. The continuous forming springback angle between the first and the ninth forming passes was only 0.5° in the paper. The peak longitudinal strain and springback are closely related to material properties.
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Funding
The authors would like to acknowledge the financial support provided by Shandong Provincial Natural Science Foundation, China (ZR2018MEE022), the National Natural Science Foundation of China (grant no.51705295), Taishan Scholarship Project of Shandong Province, China (no. tshw20130956), and Scientific Research Foundation of Shandong University of Science and Technology for Recruited Talents (2017RCJJ027).
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Su, CJ., Yang, LY., Lou, SM. et al. Research on roll forming process based on five-boundary condition forming angle distribution function. Int J Adv Manuf Technol 102, 3767–3779 (2019). https://doi.org/10.1007/s00170-019-03377-y
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DOI: https://doi.org/10.1007/s00170-019-03377-y