A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel

Abeyrathna,B, Rolfe,B, Hodgson,P and Weiss,M 2015, A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel, International Journal of Material Forming, doi: 10.1007/s12289-015-1238-7.

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Title A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel
Author(s) Abeyrathna,BORCID iD for Abeyrathna,B orcid.org/0000-0002-4476-3902
Rolfe,BORCID iD for Rolfe,B orcid.org/0000-0001-8516-6170
Weiss,MORCID iD for Weiss,M orcid.org/0000-0002-1845-6343
Journal name International Journal of Material Forming
Publisher Springer-Verlag France
Publication date 2015-04
ISSN 1960-6206
Keyword(s) Defect compensation
Longitudinal bow
Roll forming
Roll load and torque
Sensitivity study
Summary The roll forming process is increasingly used in the automotive industry for the manufacture of structural and crash components from Ultra High Strength Steel (UHSS). Due to the high strength of UHSS (<1GPa) even small and commonly observed material property variations from coil to coil can result in significant changes in material yield and through that affect the final shape of the roll formed component. This requires the re-adjustment of tooling to compensate for shape defects and maintain part geometry resulting in costly downtimes of equipment. This paper presents a first step towards an in-line shape compensation method that based on the monitoring of roll load and torque allows for the estimation of shape defects and the subsequent re-adjustment of tooling for compensation. For this the effect of material property variation on common shape defects observed in the roll forming process as well as measurable process parameters such as roll load and torque needs to be understood. The effect of yield strength and material hardening on roll load and torque as well as longitudinal bow is investigated via experimental trials and numerical analysis. A regression analysis combined with Analysis of Variance (ANOVA) techniques is employed to establish the relationships between the process and material parameters and to determine their percentage influence on longitudinal bow, roll load and torque. The study will show that the level of longitudinal bow, one of the major shape defects observed in roll forming, can be estimated by variations in roll load and torque.
Language eng
DOI 10.1007/s12289-015-1238-7
Field of Research 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, Springer Verlag
Persistent URL http://hdl.handle.net/10536/DRO/DU:30072819

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