Flange wrinkling in flexible roll forming process

Mohammad Mehdi Kasaei, Hassan Moslemi Naeini, Behnam Abbaszadeh, Mehran Mohammadi, Mojtaba Ghodsi, Manabu Kiuchi, Reza Zolghadr, Gholamhosein Liaghat, Rohollah Azizi Tafti, Mehdi Salmani Tehrani

Research output: Chapter in Book/Report/Conference proceedingConference contribution

14 Citations (Scopus)

Abstract

Flexible roll forming is an advanced sheet metal forming process for producing variable cross section profiles. Flange wrinkling at the transition zone where the cross section changes is a major defect in the flexible roll forming process. In this paper, the flange wrinkling at the transition zone is studied using finite element analysis. The results showed that the strip deformation at the transition zone can be considered as a combination of two strip deformations observed in the conventional roll forming process and the flanging process. According to finite element analysis results, when the flange wrinkling occurs, compressive longitudinal strain is smaller than the necessary compressive longitudinal strain calculated by mathematical modeling to obtain the intended profile geometry in the compression zone. Therefore, comparison of compressive longitudinal strain obtained from the finite element analysis and the necessary compressive longitudinal strain is a good criterion to predict the flange wrinkling occurrence. A flexible roll forming setup was developed. Longitudinal strain history is obtained from the finite element simulation and is compared with the experimental data from the flexible roll forming setup. Results show a good agreement and confirm the finite element analysis.

Original languageEnglish
Title of host publication11th International Conference on Technology of Plasticity, ICTP 2014
PublisherElsevier Ltd
Pages245-250
Number of pages6
Volume81
DOIs
Publication statusPublished - 2014
Event11th International Conference on Technology of Plasticity, ICTP 2014 - Nagoya, Japan
Duration: Oct 19 2014Oct 24 2014

Other

Other11th International Conference on Technology of Plasticity, ICTP 2014
CountryJapan
CityNagoya
Period10/19/1410/24/14

Keywords

  • Flexible roll forming
  • Variable cross section profiles
  • Wrinkling

ASJC Scopus subject areas

  • Engineering(all)

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    Kasaei, M. M., Naeini, H. M., Abbaszadeh, B., Mohammadi, M., Ghodsi, M., Kiuchi, M., Zolghadr, R., Liaghat, G., Tafti, R. A., & Tehrani, M. S. (2014). Flange wrinkling in flexible roll forming process. In 11th International Conference on Technology of Plasticity, ICTP 2014 (Vol. 81, pp. 245-250). Elsevier Ltd. https://doi.org/10.1016/j.proeng.2014.09.158