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Flexible roll forming of an automotive component with variable depth

conference contribution
posted on 2016-01-01, 00:00 authored by Buddhika AbeyrathnaBuddhika Abeyrathna, Bernard RolfeBernard Rolfe, L Pan, R Ge, Matthias WeissMatthias Weiss
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.



Advances in Materials and Processing Technologies. Conference (2015 : Madrid, Spain)


1 - 12


[Universidad Carlos III de Madrid]


Madrid, Spain

Place of publication

[Madrid, Spain]

Start date


End date




Publication classification

E Conference publication; E1 Full written paper - refereed

Copyright notice

[2015, The Authors]

Title of proceedings

AMPT 2015 : Notes from the Materials and Processing Technologies Conference

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