Numerical and Experimental Analysis of Spring-back Defect in Flexible Roll Forming Process using Anisotropic Yield Criteria

Authors

1 Assis. Prof., Dep. of Mech. Eng., Shahid Rajaee Teacher Training University, Tehran, Iran

2 Assistant professor/ Depatment of mechanical engineering/ Faculty of Engelab-e Eslami/ Technical and Vocational University (TVU)

3 Shahid Rajaee Teacher Training University, Tehran, Iran

Abstract

The Flexible Roll Forming (FRF) process with the ability to produce parts with variable width and depth was formed to be used in industries such as automotive, construction, and similar industries. One of the disadvantages of this process is the spring-back defect, which prevents the desired profile from being achieved. In this paper, experimental and numerical analysis of the spring-back phenomenon using Hill, Barlat, and Von Mises yield criteria. Also, the effect of bending angle, material, and sheet thickness parameters on this defect was investigated. The process for the three types of 1050 aluminum, low carbon steel, and 430 stainless steel was simulated using the VUMAT subroutine of Abaqus software. In these simulations, for each material, three thicknesses of 0.4, 0.7 and 1 mm with bending angles of 25 and 45 degrees were considered. Experimental experiments were performed using the FRF machine. Validation of numerical simulation results was performed by comparing experimental results. The results showed that the Barlat criterion has a more accurate prediction of spring-back than the other two criteria. The results also showed that the spring-back ratio of sheets with a thickness of 0.4 mm compared to 1 mm for low carbon, aluminum, and stainless steel are 1.5, 2.5, and 3.2, respectively.

Keywords

References

[1] Storbeck M, Beiter P, Berner S, Brenneis M, Schmitt W, Groche P (2012) Lightweight Products by Load Optimized Profile Design. Future Trends in Production Engineering 161-179.
[2] Jiao J, Rolfe B, Mendiguren J, Weiss M (2015) An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width. Int J Mech Sci 90: 228-238.
[3] Dadgar Y, Sheikhi MM, Anaraki AP, Gollo MH, Panahizadeh V (2017) Fracture analysis on flexible roll forming process of anisotropic Al6061 using ductile fracture criteria and FLD. Int J Adv Manu Technol 91(5-8): 1481-1492.
 [4] Gulceken E, Abeé A, Sedlmaier A, Livatyali H (2007) Finite element simulation of flexible roll forming, A case study on variable width U channel. 4th Int. Conf. Exhibition on Desing and Production of Machines and Dies/Molds, Turkey.
[5] Groche P, Henkelmann M, Gotz P, Berner S (2008) Cold rolled profiles for vehicle construction. Arch. of Civil & Mech. Eng. 8(2): 31-38.
[6] Larrañaga J, Galdos L (2009) Geometrical accuracy improvement of flexibly roll formed  profiles by means of local heating. First Int Con Roll Forming, Spain.
[7] Kasaei MM, MoslemiNaeini H, Abbaszadeh B, Mohammadi M, Ghodsi M, Kiuchi M, Zolghadr R, Liaghat Gh, AziziTafti R, Salmani Tehrani M (2014) Flange wrinkling in flexible roll forming process. Pro Eng 81: 245-250.
[8] Mohammadi M, MoslemiNaeini H, Kasaei MM, Salmani Tehrani M, Abbaszadeh B (2014) Investigation of web warping of profiles with changing cross section inflexible roll forming process. Modares Mechanical Engineering 14(6): 72-80.
[9] Yan Y, Wang H, Li Q, Qian B, Mpofu Kh (2014) Simulation and experimental verification of flexible roll forming of steel sheets. Int J Adv Manuf Technol, London.
[10] Dadgar Asl Y, Sheikhi MM, Pourkamali Anaraki A, Panahizadeh Rahimloo V, Hosseinpour Gollo M (2016) Experimental and Numerical Analysis of Fracture on Flexible Roll Forming Process of Channel Section in Aluminum 6061-T6 Sheet. Modares Mechanical Engineering 16(5): 329-338
[11] پناهی زاده و (1392) بررسی نظری، تجربی و عددی عیب برگشت فنری و پیش‌بینی شکست در فرایند شکل‌دهی غلتکی سرد با استفاده از معیارهای شکست نرم. پایان‌نامه دکتری، دانشگاه تربیت ‌مدرس.
 [12] Hill R (1948) A theory of the yielding and plastic flow of anisotropic metals. P Roy Soc A-Math Phy 193: 281-297.
[13] Barlat F, Lege DJ, Brem JC (1991) A six-component yield function for anisotropic materials. Int J Plasticity 7: 693-712.
Journal of Solid and Fluid Mechanics
Volume 11, Issue 4
November and December 2021
Pages 93-105

Files

Share

How to cite

Statistics