Numerical analysis of the flexible roll forming of an automotive component from high strength steel Abeyrathna, B., Abvabi, A., Rolfe, B., Taube, R. and Weiss, M. 2016, Numerical analysis of the flexible roll forming of an automotive component from high strength steel, in IDDRG 2016 : Challenges in Forming High-Strength Sheets : Proceedings of the IOP Conference Series Materials Science and Engineering, IOP Publishing, Bristol, Eng., pp. 1-9, doi: 10.1088/1757-899X/159/1/012005. Attached Files Name Description MIMEType Size Downloads Title Numerical analysis of the flexible roll forming of an automotive component from high strength steel Author(s) Abeyrathna, B. orcid.org/0000-0002-4476-3902 Abvabi, A. Rolfe, B. orcid.org/0000-0001-8516-6170 Taube, R. Weiss, M. Conference name Materials Science and Engineering. IOP Conference Series (2016 : Linz, Austria) Conference location Linz, Austria Conference dates 2016/06/12 - 2016/06/15 Title of proceedings IDDRG 2016 : Challenges in Forming High-Strength Sheets : Proceedings of the IOP Conference Series Materials Science and Engineering Publication date 2016 Conference series Materials Science and Engineering IOP Conference Series Start page 1 End page 9 Total pages 9 Publisher IOP Publishing Place of publication Bristol, Eng. Summary Conventional roll forming is limited to components with uniform cross-section; the recently developed flexible roll forming (FRF) process can be used to form components which vary in both width and depth. It has been suggested that this process can be used to manufacture automotive components from Ultra High Strength Steel (UHSS) which has limited tensile elongation. In the flexible roll forming process, the pre-cut blank is fed through a set of rolls; some rolls are computer-numerically controlled (CNC) to follow the 3D contours of the part and hence parts with a variable cross-section can be produced. This paper introduces a new flexible roll forming technique which can be used to form a complex shape with the minimum tooling requirements. In this method, the pre-cut blank is held between two dies and the whole system moves back and forth past CNC forming rolls. The forming roll changes its angle and position in each pass to incrementally form the part. In this work, the process is simulated using the commercial software package Copra FEA. The distribution of total strain and final part quality are investigated as well as related shape defects observed in the process. Different tooling concepts are used to improve the strain distribution and hence the part quality. ISSN 1757-8981 1757-899X Language eng DOI 10.1088/1757-899X/159/1/012005 Field of Research 099999 Engineering not elsewhere classified MD Multidisciplinary Socio Economic Objective 0 Not Applicable HERDC Research category E1 Full written paper - refereed Copyright notice ©2016, The Authors Persistent URL http://hdl.handle.net/10536/DRO/DU:30092396 Document type: Conference Paper Collections: School of Engineering Institute for Frontier Materials Open Access Checking Related Links Link Description Connect to published version Go to link with your DU access privileges   Connect to Elements publication management system Go to link with your DU access privileges     Unless expressly stated otherwise, the copyright for items in DRO is owned by the author, with all rights reserved. Versions Version Filter Type Wed, 29 Mar 2017, 06:59:04 EST Wed, 29 Mar 2017, 11:05:28 EST Wed, 29 Mar 2017, 11:12:15 EST Mon, 03 Apr 2017, 09:08:11 EST Mon, 03 Apr 2017, 09:12:51 EST Tue, 04 Apr 2017, 06:05:08 EST Mon, 10 Jul 2017, 09:57:06 EST Mon, 10 Jul 2017, 10:00:47 EST Mon, 10 Jul 2017, 10:01:50 EST Filtered Full Citation counts:   Cited 0 times in TR Web of Science Cited 0 times in Scopus Search Google Scholar Access Statistics: 9 Abstract Views, 3 File Downloads  -  Detailed Statistics Created: Mon, 03 Apr 2017, 09:12:51 EST

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