A numerical analysis on web-warping and profile accuracy in the flexible roll forming of AHSS

Flexible roll forming is a new sheet metal forming technology that allows the manufacture of materials with high strength to complex and weight optimised components and therefore represents a cost effective alternative for the manufacture of automotive parts from advanced high strength steel (AHSS). Web-warping as a critical shape error limits the application of the process in automotive manufacturing. This paper investigates numerically the effects of parameters of flexible roll forming process on the web-warping defect and profile shape accuracy. The results show that, process design parameters significantly affect web-warping and profile accuracy in flexible roll forming and that compared to Mild steel (MS), AHSS material can show superior performance with respect to profile shape accuracy.