Part quality improvement in flexible roll forming of a combined variable width and depth component

Abstract Flexible Roll Forming (FRF) is an advanced manufacturing process that can be used to form long and complex part families from hard to form materials for the automotive and truck industry. However, depending on the part complexity and material strength shape defects such as end flare, springback and twist can occur. In this work a high strength automotive part (Sled runner) is produced from 3 high strength steels; the complex component combines shape variations in width and depth. The optimum forming sequence is identified to produce the part without any flange wrinkles. In addition to this, a new over forming technique is introduced to overcome end flare and springback. The experimental results are evaluated and discussed with numerical analysis and suggest that the presented forming technology enables the manufacture of high strength components in accordance with automotive specifications and quality standards.