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Flexible roll forming of an automotive component with variable depth

Abeyrathna, Buddhika, Rolfe, Bernard, Pan, Libo, Ge, Rui and Weiss, Matthias 2015, Flexible roll forming of an automotive component with variable depth, in AMPT 2015 : Notes from the Materials and Processing Technologies Conference, [Universidad Carlos III de Madrid], [Madrid, Spain], pp. 1-12.

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Title Flexible roll forming of an automotive component with variable depth
Author(s) Abeyrathna, BuddhikaORCID iD for Abeyrathna, Buddhika orcid.org/0000-0002-4476-3902
Rolfe, BernardORCID iD for Rolfe, Bernard orcid.org/0000-0001-8516-6170
Pan, Libo
Ge, Rui
Weiss, Matthias
Conference name Advances in Materials and Processing Technologies. Conference (2015 : Madrid, Spain)
Conference location Madrid, Spain
Conference dates 14-17 Dec. 2015
Title of proceedings AMPT 2015 : Notes from the Materials and Processing Technologies Conference
Publication date 2015
Start page 1
End page 12
Total pages 12
Publisher [Universidad Carlos III de Madrid]
Place of publication [Madrid, Spain]
Keyword(s) finite element analysis
flexible rolling form
UHSS
variable depth rolling form
Summary Roll forming is a cost and energy efficient process for the manufacture of Ultra High Strength Steel (UHSS) structural and crash components in the automotive industry. The conventional roll forming process is limited to component having constant cross-section, while the recently deveoped Flexible Roll Forming (FRF) process allows the production of components in which the section varies over the length of the aprt; this permits optimization in terms of strength and weight. There has been an uptake in FRF in the heavy vehicle industry for the production of long and high strength structural parts, but passenger car bodies are more complex and generally parts require variations in width and also in depth. The widespread application of FRF in the automotive industy therefore requires the forming of components that have intricate variations in profile depth over the length of the part.
This work is a first comprehensive study of the FRF of high strength structural components with variable depth. For this, the FRF of an automotive bumper section is analyzed numerically using the commercial software package COPRA® FEA RF. A detailed analysis of the distribution and history of plastic strain in longitudinal, transcerse and thickness directions is performed and related to the shape defects observed in the proecss. The analysis shows that when forming variable depth components, zones of compressive longitudinal strain exist that lead to wrinkling defects. These can be reduced by applying additional flange contact during the operation. In general the current work suggests that the FRF of high strength components with variable depth is possible and can compete with other forming methods currently used in the automotive industry.
Language eng
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
Socio Economic Objective 961205 Rehabilitation of Degraded Mining Environments
HERDC Research category E1 Full written paper - refereed
ERA Research output type E Conference publication
Copyright notice ©[2015, The Authors]
Persistent URL http://hdl.handle.net/10536/DRO/DU:30081655

Document type: Conference Paper
Collections: Institute for Frontier Materials
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