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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.

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Title Numerical analysis of the flexible roll forming of an automotive component from high strength steel
Author(s) Abeyrathna, B.ORCID iD for Abeyrathna, B. orcid.org/0000-0002-4476-3902
Abvabi, A.
Rolfe, B.ORCID iD for Rolfe, B. orcid.org/0000-0001-8516-6170
Taube, R.
Weiss, M.ORCID iD for Weiss, M. orcid.org/0000-0002-1845-6343
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
Free to Read? Yes
Use Rights Creative Commons Attribution licence
Persistent URL http://hdl.handle.net/10536/DRO/DU:30092396

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Every reasonable effort has been made to ensure that permission has been obtained for items included in DRO. If you believe that your rights have been infringed by this repository, please contact drosupport@deakin.edu.au.