An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width

Jiao,J, Rolfe,B, Mendiguren,J and Weiss,M 2015, An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width, International Journal of Mechanical Sciences, vol. 90, pp. 228-238, doi: 10.1016/j.ijmecsci.2014.11.010.

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Title An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width
Author(s) Jiao,J
Rolfe,BORCID iD for Rolfe,B orcid.org/0000-0001-8516-6170
Mendiguren,J
Weiss,MORCID iD for Weiss,M orcid.org/0000-0002-1845-6343
Journal name International Journal of Mechanical Sciences
Volume number 90
Start page 228
End page 238
Publisher Elsevier Ltd
Publication date 2015-01
ISSN 0020-7403
Keyword(s) Flexible roll forming
Longitudinal strain
UHSS
Web-warping
Summary To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steel (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional stamping. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process, which allows the manufacture of metal sheet with high strength and limited ductility into complex and weight-optimized components. One major problem in the flexible roll forming of UHSS is the web-warping defect, which is the deviation in height of the web area over the length of the profile. It has been shown that web-warping is strongly dependant to the permanent longitudinal strain formed in the flange of the part. Flexible roll forming is a continuous process with many roll stands, which makes numerical analysis extremely time intensive and computationally expensive. An analytical model of web-warping is therefore critical to improve design efficiency during the early process design stage before FEA is applied. This paper establishes for the first time an analytical model for the prediction of web-warping for the flexible roll forming of a section with variable width. The model is based on evaluating longitudinal edge strain in the flange of the part. This information is then used in combination with a simple geometrical model to investigate the relationship between web-warping and longitudinal strain with respect to process parameters.
Language eng
DOI 10.1016/j.ijmecsci.2014.11.010
Field of Research 091307 Numerical Modelling and Mechanical Characterisation
091006 Manufacturing Processes and Technologies (excl Textiles)
Socio Economic Objective 861205 Sheet Metal Products
HERDC Research category C1 Refereed article in a scholarly journal
Copyright notice ©2015, Elsevier
Persistent URL http://hdl.handle.net/10536/DRO/DU:30069950

Document type: Journal Article
Collections: Institute for Frontier Materials
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