Assesment of roll-formed products including the cold forming effects

Güner, Alper
Roll-forming is an efficient sheet forming process that is used in manufacturing long parts with constant cross-section. The theoretical, experimental and numerical analyses of the process are limited since the sheet takes a complex 3D shape during the process. In this study proper finite element method models to simulate the roll-forming process are examined both numerically and experimentally. In addition, the applicability of 2D plane strain models to the simulation of the process is investigated. To reveal the deformation of the sheet, important geometrical parameters of the sheet and the rollers are introduced. The effect of these parameters on the strain hardening and deformation of the sheet is analyzed at distinct parts of the sheet that undergoes different types of deformations. Having revealed the deformation mechanisms, the assumptions behind the theoretical knowledge is criticized. The mentioned studies are verified with a case study in which a roll-formed product is analyzed under service loads. The manufacturing of the product and service load application are simulated and the results are compared with the experiments. In addition, effects of cold forming on the behaviour of the product under service loads are examined. It is concluded that under some conditions, 2D plane strain simulations can be used to predict the strain hardening in the material that occurs during roll-forming and this hardening has a considerable effect on the response of the material under loading.


Modeling of resin transfer molding for composites manufacturing
İpek, Hakan; Erdal Erdoğmuş, Merve; Department of Mechanical Engineering (2005)
The resin transfer molding (RTM ) process, in which a thermosetting resin is injected into a mold cavity preloaded with a porous fiber preform, is a manufacturing method for producing advanced continuous fiber reinforced composite products with complex geometries. Numerical simulation of resin transfer molding process is an often needed tool in manufacturing design, in order to analyze the process before the mold is constructed. In this study, a numerical simulation of the resin impregnation process in RTM ...
Modeling of particle filled resin impregnation in compression resin transfer molding
Şaş, Hatice Sinem; Erdal Erdoğmuş, Merve; Department of Mechanical Engineering (2010)
Compression Resin Transfer Molding (CRTM) is an advanced liquid molding process for producing continuous fiber-reinforced composite parts in relatively large dimensions and with high fiber volume fractions. This thesis investigates this process for the purpose of producing continuous fiber reinforced composites with particle fillers. In many composites, fillers are used within the resin for various reasons such as cost reduction and improvement of properties. However, the presence of fillers in a process in...
Exact solution of rotating FGM shaft problem in the elastoplastic state of stress
Akis, Tolga; Eraslan, Ahmet Nedim (Springer Science and Business Media LLC, 2007-10-01)
Plane strain analytical solutions to estimate purely elastic, partially plastic and fully plastic deformation behavior of rotating functionally graded (FGM) hollow shafts are presented. The modulus of elasticity of the shaft material is assumed to vary nonlinearly in the radial direction. Tresca's yield criterion and its associated flow rule are used to formulate three different plastic regions for an ideal plastic material. By considerina different material compositions as well as a wide range of bore radi...
Development of postprocessor, simulation and verification software for a five-axis CNC milling machine
Cengiz, Ender; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2005)
Five-axis CNC milling machine tools bring great facility to produce complex workpieces with increased dimensional accuracy and better surface quality in shorter machining times. However, kinematics of five-axis machine tools has a complex form which makes it difficult to operate these machine tools properly. The difficulty arises from the complexity of NC-Code generation and tool path verification. Collision of machine tool or setup components with each other is a severe problem in five-axis machining opera...
Design of a touch trigger probe for a coordinate measuring machine
Karuç, Emre; Dölen, Melik; Department of Mechanical Engineering (2007)
Coordinate Measuring Machines (CMMs) have been widely used in industry in order to determine the form / dimensional tolerances of workpieces with very complicated geometrical shapes. Therefore, CMM is an important tool during the manufacturing and quality control phases. Workpiece to be measured on a CMM is probed via touch trigger probe through its stylus tip. In other words, by virtue of the touch trigger probes CMM can acquire the dimensional data of the workpiece that is to be measured. Therefore the pr...
Citation Formats
A. Güner, “Assesment of roll-formed products including the cold forming effects,” M.S. - Master of Science, Middle East Technical University, 2007.