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Sattar, S., Mazdak, S., Sharifi, E. (2017). Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming Process. ADMT Journal, 10(2), 121-131.
S. Sattar; S. Mazdak; E. Sharifi. "Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming Process". ADMT Journal, 10, 2, 2017, 121-131.
Sattar, S., Mazdak, S., Sharifi, E. (2017). 'Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming Process', ADMT Journal, 10(2), pp. 121-131.
Sattar, S., Mazdak, S., Sharifi, E. Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming Process. ADMT Journal, 2017; 10(2): 121-131.

Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming Process

Article 12, Volume 10, Issue 2, Spring 2017, Page 121-131  XML PDF (1.42 MB)
Document Type: Original Article
Authors
S. Sattar; S. Mazdak email ; E. Sharifi
Department of Mechanical Engineering, University of Tafresh, Iran
Abstract
Cold roll forming is a process in which a metal sheet gets a desired section form by passing through a series of rotating rollers. Predicting the amount of the distortion in pre-notched cold formed sections still remains challenging in cold roll forming industry, depending on the shape and position of the holes. This study investigates the influence of variation of the design parameters on the defects of the U-channel sections produced by cold roll forming process with circular pre-notches.  To analyze the important parameters in deforming the circular holes during the cold roll forming of U-channel sections, a three-dimensional finite element model has been taken into account. A range of variation for design factors in forming the U-channel sections with pre-notches is set, including radius of circular holes, distance between the holes and the flange edge, hole spacing, sheet thickness, and type of material. Furthermore, using the response surface methodology, a set of tests are designed and modeled employing Finite Element analysis. Afterward, a set of output parameters such as edge buckling, the wave of the holes, the change in hole size, hole spacing, and the distance between the holes and the edge of the flange, are considered. Utilizing Analyses Of Variance (ANOVA), the accuracy of the linear regression models was conducted in this study. The accuracy of the simulated models is examined by comparing the analysis results with the experimental results. Finally, the effect of the important parameters on the defects of the product has been extracted in both the statistical form as well as mathematical functions applying response surface methodology. The results show that as the radius of the hole increases, edge buckling increases. The increase of the hole radius increases the edge wave on the holes. The hole width of the product is bigger and the hole length is smaller than the nominal measuring.
Keywords
Cold roll forming; Finite Element; Pre-notched sheet; Response Surface Method; U-channel section
References

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[2]   Salmani Tehrani, M., Hartley, P., Moslemi Naeini, H., and Khademizadeh, H., “Localised edge Buckling in Cold Roll-forming of Symmetric Channel Section”, Thin-Walled Structures, Vol. 44, 2006, pp. 184–196.

[3]  Bhattacharyya, D., Smith, P. D., Yee, C. H., and Collins, L. F., “The Prediction of Deformation Length in Cold Roll Forming”, J. Mech. Work Tech., Vol. 9, 1984, pp. 181-191.

[4]   Chiang, K. F., “Cold Roll Forming”, ME Thesis, University of Auckland, 1984.

[5]   Brunet, M., Lay, B., and Pol, P., “Computer Aided Design of Roll Forming of a Channel Section”, J. Mater. Process Technol., Vol 60, 1966, pp. 209-214.

[6]   Watari, H., Ona, H., “Characteristic Features of Shape Defects Occurring in the Cold Roll Forming of Pre-notched Products”, Journal of Materials Processing Technology, Vol. 80–8, 1998, pp. 225-231.

[7]   Brunet, M., Lay, B., and Pol, P., “Computer Aided Design of Roll Forming of a Channel Section”, J. Mater. Process Technol., Vol 60, 1966, pp. 209-214.

[8]   Han, Z. H., “The Effects of Forming Parameters in the Roll Forming of a Channel Section with an outer Edge”, J. Mater. Process Technol., Vol. 116, 2001, pp. 205-210.

[9]       Lindgren, M., “Cold Roll Forming of a U-channel Made of High Strength Steel”, Journal of Materials Processing Technology, Vol. 186, 2007, pp. 77–81.

[10]    Chiang, K. F., “Cold Roll Forming”, ME Thesis, University of Auckland, 1984.

[11]    Bui, Q. V., Ponthot, J. V., “Numerical Simulation of Cold Roll Forming Processes”, Journal of Mater Process Technology, Vol, 202, 2008, pp. 275-282.

[12]     Zeng, G., Li, S. H., Yu, Z. Q., and Lai, X. M., “Optimization Design of Roll Profiles for Cold Roll Forming Based on Response Surface Method”, Materials and Design, Vol, 30, 2009, pp. 1930–1938.

[13]    Zeng, G., Li, S. H., Yu, Z. Q., and Lai, X. M., “Optimization Design of Roll Profiles for Cold Roll Forming Based on Response Surface Method”, Materials and Design, Vol, 30, 2009, pp. 1930–1938.

[14]     Watari, H., Ona, H., “Characteristic Features of Shape Defects Occurring in the Cold roll Forming of Pre-notched Products”, Journal of Materials Processing Technology, Vol. 80–8, 1998, pp. 225-231.

[15]    Brunet, M., Lay, B., and Pol, P., “Computer Aided Design of Roll Forming of a Channel Section”, J. Mater. Process Technol., Vol 60, 1966, pp. 209-214.

[16]    Han, Z. H., “The Effects of Forming Parameters in the Roll Forming of a Channel Section with an outer Edge”, J. Mater. Process Technol., Vol., 116, 2001, pp. 205-210.

[17]    Lindgren, M., “Cold Roll Forming of a U-channel Made of High Strength Steel”, Journal of Materials Processing Technology, Vol. 186, 2007, pp.77–81.

[18]    Chiang, K. F., “Cold Roll Forming”, ME Thesis,         University of Auckland, 1984.

[19]    Bui, Q. V., Ponthot, J. V., “Numerical Simulation of Cold Roll Forming Processes”, Journal of Mater Process Technology, Vol, 202, 2008, pp. 275-282.

[20]    Zeng, G., Li, S. H., Yu, Z. Q., and Lai, X. M., “Optimization Design of Roll Profiles for Cold Roll Forming Based on Response Surface Method”, Materials and Design, Vol, 30, 2009, pp. 1930-1938.

[21]    Moslemi Naeini, H., Bidabadi Shirani, B., Mazdak, S., Aziz Tafti, R., and Nemati Faghir, A., “Numerical Analysis of Effective Parameters on the Steel Profiles in Cold Roll Forming Process of Pre notch Sheets,” 20th annual international Iranian mechanical engineering conference, 2012.

[22]    Halmos, G. T., “Roll Forming Handbook”, Taylor & Francis Group, 2006, Chap. 4.

[23]    Handbook for Experimenters, Version 10.01., http://www.statease.com.

[24]    Shirani Bidabadi, B., “Numerical and Experimental Study of Transforming the Hole in Cold Roll Forming Process of Pre notch Section,” M.Sc. thesis, University of Tarbiat Modares, 2013.

[25]    Shirani Bidabadi, B., Moslemi Naeini, H., Azizi Tafti, R., and Mazdak, S., “Experimental Investigation of the Ovality of Holes on Pre-notched Channel Products in the Cold Roll Forming Process”, Journal of Materials Processing Technology, Vol. 225, 2015, pp. 213-220.

 

 

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