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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.