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A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel

  • Thematic Issue: Flexible forming - Incremental Sheet Forming & Roll Forming
  • Published:
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Abstract

The roll forming process is increasingly used in the automotive industry for the manufacture of structural and crash components from Ultra High Strength Steel (UHSS). Due to the high strength of UHSS (<1GPa) even small and commonly observed material property variations from coil to coil can result in significant changes in material yield and through that affect the final shape of the roll formed component. This requires the re-adjustment of tooling to compensate for shape defects and maintain part geometry resulting in costly downtimes of equipment. This paper presents a first step towards an in-line shape compensation method that based on the monitoring of roll load and torque allows for the estimation of shape defects and the subsequent re-adjustment of tooling for compensation. For this the effect of material property variation on common shape defects observed in the roll forming process as well as measurable process parameters such as roll load and torque needs to be understood. The effect of yield strength and material hardening on roll load and torque as well as longitudinal bow is investigated via experimental trials and numerical analysis. A regression analysis combined with Analysis of Variance (ANOVA) techniques is employed to establish the relationships between the process and material parameters and to determine their percentage influence on longitudinal bow, roll load and torque. The study will show that the level of longitudinal bow, one of the major shape defects observed in roll forming, can be estimated by variations in roll load and torque.

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Acknowledgments

The authors appreciate the financial support of the Australian Research Council (ARC Linkage grant - LP120100111) and thank data M sheet metal solutions for providing several licences of Copra RF/FEA. The authors further would like to thank Emeritus Professor J.L. Duncan for his assistance in writing this paper and appreciate the support of Dr. Joseba Mendiguren, Mr. Ahmad Erfani and Mrs. Shiromani Desinghe.

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Authors and Affiliations

  1. Institute for Frontier Materials, Deakin University, Pigdons Rd., Waurn Ponds, VIC, 3216, Australia

    Buddhika Abeyrathna, Peter Hodgson & Matthias Weiss

  2. School of Engineering, Deakin University, Pigdons Rd., Waurn Ponds, VIC, 3216, Australia

    Bernard Rolfe

Authors
  1. Buddhika Abeyrathna
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  2. Bernard Rolfe
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  3. Peter Hodgson
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  4. Matthias Weiss
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Correspondence to Buddhika Abeyrathna.

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Abeyrathna, B., Rolfe, B., Hodgson, P. et al. A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel. Int J Mater Form 9, 423–434 (2016). https://doi.org/10.1007/s12289-015-1238-7

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  • DOI: https://doi.org/10.1007/s12289-015-1238-7

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