Skip to main content
SpringerLink
Log in

End flare of linear flow split profiles

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

One approach to design load optimized structures is the use of bifurcations. Linear flow splitting is a continuous sheet-bulk metal forming process, whereby bifurcated profiles are manufactured without joining or external heat supply. By roll forming linear flow split profiles, a wide spectrum of profile geometries can be realized, e.g. multi-chamber-profiles. Those profiles often require high dimensional accuracy to ensure their functionality. During roll forming, process related residual stresses are induced, which are released when the profiles are cut to length. Thereby increased deformation at the profile ends occurs, also known as end flare. End flare of bifurcated profiles has not been investigated so far. The aim of this research is to investigate end flare after roll forming of linear flow split profiles. Therefore, end flare after roll forming of a conventional sheet metal and a linear flow split profile is compared. The effect of residual stresses induced by linear flow splitting as well as the effect of additional geometrical stiffness due to the bifurcations on the development of end flare are examined. It is found that the residual stresses induced by linear flow splitting have no significant effect on end flare. However, the geometrical bifurcation affects the roll forming process, leading to higher residual stresses in the flange, which significantly affect the magnitude and the direction of end flare.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

References

  1. Groche P, Bruder E, Gramlich S (2017) Manufacturing integrated design – sheet metal product and process innovation, Springer international publishing AG

  2. Groche P, Ringler J, Vucic D (2007) New forming processes for sheet metal with large plastic deformation. Key Eng Mater 344:251–258

    Article  Google Scholar 

  3. Groche P, Vucic D, Jöckel M (2006) Basics of linear flow splitting. J Mater Process Technol 183:249–255

    Article  Google Scholar 

  4. Groche P, Vucic D (2006) Multi-chambered profiles made from high-strength sheets. Production Engineering, Annals of the WGP 3:67–70

    Google Scholar 

  5. Halmos G (2005) Roll forming handbook. CRC Press, Boca Raton

    Book  Google Scholar 

  6. Sweeney K, Grunewald U (2003) The application of roll forming for automotive structural parts. J Mater Process Technol 132(1-3):9–15

    Article  Google Scholar 

  7. Moneke M, Groche P (2017) Counter measures to effectively reduce end flare, AIP Conference Proceedings 1896, pp. 020006–1 – 020006–6

  8. Lange K (1990) Handbook of metal forming – volume 3, Society of Manufacturing Engineers

  9. Zhu S, Panton S, Duncan J (1996) The effects of geometric variables in roll forming a channel section. Proceedings of The Institution of Mechanical Engineers Part B-journal of Engineering Manufacture - PROC INST MECH ENG B-J ENG MA 210(2):127–134

    Article  Google Scholar 

  10. Abeyrathna B, Rolfe B, Hodgson P, Weiss M (2017) Local deformation in roll forming. Int J Adv Manuf Technol 88(9–12):2405–2415

    Article  Google Scholar 

  11. Bhattacharyya D, Smith P, Yee C, Collins I (1984) The prediction of deformation length in cold roll-forming. J Mech Work Technol 9(2):181–191

    Article  Google Scholar 

  12. Abeyrathna B, Rolfe B, Weiss M (2017) The effect of process and geometric parameters on longitudinal edge strain and product defects in cold roll forming. Int J Adv Manuf Technol 92(1–4):746–754

    Google Scholar 

  13. Paralikas J, Salonitis K, Chrydssolouris G (2009) Investigation of the effects of main roll forming process parameters on quality for a V-section profile from AHSS. Int J Adv Manuf Technol 44(3–4):223–237

    Article  Google Scholar 

  14. Han Z, Liu C, Lu W, Ren L (2001) The effects of forming parameters in the roll-forming of a channel section with an outer edge. J Mater Process Technol 116(2-3):205–210

    Article  Google Scholar 

  15. Saffe S, Nagamachi T, Ona H (2015) Mechanism of end deformation after cutting of light Gauge Channel steel formed by roll forming. Mater Trans 56(2):187–192

    Article  Google Scholar 

  16. Quach W, Teng J, Chung K (2004) Residual stresses in steel sheets due to coiling and uncoiling - a closed-form analytical solution. Eng Struct 26(9):1249–1259

    Article  Google Scholar 

  17. Weiss M, Abeyrathna B, Rolfe B, Abee A, Wolfkamp H (2017) Effect of coil set on shape defects in roll forming steel strip. J Manuf Process 25:8–15

    Article  Google Scholar 

  18. Weiss M, Rolfe B, Hodgson P, Yang C (2012) Effect of residual stress on the bending of aluminium. J Mater Process Technol 212(4):877–883

    Article  Google Scholar 

  19. Abvabi RB, Hodgson P, Weiss M (2015) The influence of residual stress on a roll forming process. Int J Mech Sci 101-102:124–136

    Article  Google Scholar 

  20. Ludwig C, Hammen V, Groche P, Kaune V, Müller C (2013) Manufacturing of quality optimized linear flow split parts by variation of fast modifiable process parameters and their influence on material characteristics. Mat-wiss u Werkstofftech 44(7):601–611

    Article  Google Scholar 

  21. Groche P, Monnerjahn V, Özel M, Yu Y (2017) Remote joining by plastic deformation in the process of linear flow splitting. J Mater Process Technol 246:262–266

    Article  Google Scholar 

  22. Görtan M, Vucic D, Groche P, Livatyali H (2009) Roll forming of branched profiles. J Mater Process Technol 209(17):5837–5844

    Article  Google Scholar 

  23. Bruder E, Ahmels L, Niehuesbernd J, Müller C (2017) Manufacturing-induced material properties of linear flow split and linear bend split profiles. Mat-wiss u Werkstofftech 48(1):41–52

    Article  Google Scholar 

  24. Liu C, Zhou W, Fu X, Chen G (2015) A new mathematical model for determining the longitudinal strain in cold roll forming process. Int J Adv Manuf Technol 79(5–8):1055–1061

    Article  Google Scholar 

  25. Görtan O, Ludwig C, Groche P, Livatyali H (2009) Finite Element Simulation of Roll Forming Process of Branched Profiles, 5th International Conference and Exhibition on Design and Production of Machines and Dies/Molds, 18–21 June 2009, Kusadasi, Aydin, Turkey

  26. Wagner C, Gramlich S, Monnerjahn V, Groche P, Kloberdanz H (2015) Technology pushed process and product innovation – joining by linear flow splitting. Procedia CIRP 37:83–88

    Article  Google Scholar 

  27. Monnerjahn V, Lobers M, Groche P (2017) Simultaneous Forming and Joining by Linear Flow Splitting – From Basic Mechanisms to the Continuous Manufacturing Line, Procedia Engineering, Vol. 207, pp. 962–967

  28. Rullmann F, Abrass A, Kruse M, Groche P (2012) The Cut-Expand-Method for the FE-simulation of steady-state rolling processes, Metal Forming. Wiley-VCH Verlag GmbH & Co., Weinheim, Germany

    Google Scholar 

  29. Rullmann F, Bauer O, Landersheim V, Groche P, Hanselka H (2012) Numerische durchgängige Prozessketten- bewertung mittels FEM, in 4. Zwischenkolloquium des Sonderforschungsbereich 666:109–120

    Google Scholar 

  30. Müller C, Bohn T, Bruder E, Bruder T, Landersheim V, Dsoki C, Groche P, Veleva D (2007) Severe plastic deformation by linear flow splitting. Mat-wiss u Werkstofftech 38(10):842–854

    Article  Google Scholar 

  31. Bruder E, Bohn T, Müller C (2008) Properties of UFG HSLA Steel Profiles Produced by Linear Flow Splitting. Mater Sci Forum 584–586:661–666

    Article  Google Scholar 

Download references

Acknowledgements

The investigations presented in this paper are supported by the German Research Foundation (DFG). The authors would like to thank DFG for funding the Collaborative Research Centre 666 “Integral sheet metal design with higher order bifurcations – Development, Production, Evaluation”.

Funding

This study was funded by the German Research Foundation (DFG) as part of Collaborative Research Center 666 (CRC 666).

Author information

Authors and Affiliations

  1. Technische Universität Darmstadt, Institute for Production Engineering and Forming Machines, 64287, Darmstadt, Germany

    M. Moneke, P. Mahajan & P. Groche

Authors
  1. M. Moneke
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Mahajan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. P. Groche
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Moneke.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Moneke, M., Mahajan, P. & Groche, P. End flare of linear flow split profiles. Int J Mater Form 12, 429–440 (2019). https://doi.org/10.1007/s12289-018-1426-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-018-1426-3

Keywords

Search

Navigation