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On feasibility of roll-stamp forming variable-sectional metal channels

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Abstract 

Sheet metal channels with variable sections or local features have been widely used in automobile and construction industries, and novel forming techniques, such as flexible roll forming process, flexibly reconfigurable roll forming process, Deakin’s flexible forming facility, and chain-die forming recently have been developed to manufacture those channels. In this paper, the feasibility of chain-die forming technique to manufacture channels with variable sections is systematically investigated through experiment and finite element simulation by taking 6 types of channel products as demonstration, including three variable-width and three variable-depth profiles. The forming process of the channels shows a combination of roll forming and stamping, and this roll-stamp mode has great potential in manufacturing a wide variety of channels with variable cross-sections. The formability for roll-stamp forming variable-depth channels is evaluated through finite element simulation and forming limit diagram. The roll-stamp mode can be discomposed into roll forming longitudinally and stamping vertically, and can achieve a reduction in forming load by the maximum of 33.9% compared with the conventional stamping in forming the flange step product. The forming direction sensitivity of the variable-width feature is discussed from the aspect of web arch height development.

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Acknowledgements

The authors would like to acknowledge the support of the National Natural Science Foundation of China (grant no. U1860110). And the authors would like to thank CRRC Changchun Railway Vehicles Co, Ltd. for providing manufacturing assistance.

Funding

This work was supported by the National Natural Science Foundation of China (grant no. U1860110).

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Author notes

  1. Kaijun Lu and Zhenye Liang contributed equally to this work.

Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, China

    Kaijun Lu, Zhenye Liang, Tianxia Zou, Yongkai Wang, Dayong Li & Yinghong Peng

  2. School of Mechanical and Mining Engineering, The University of Queensland, St Lucia, Brisbane, QLD, 4072, Australia

    Shichao Ding

  3. State Key Laboratory of Development and Application Technology of Automotive Steels (BaoSteel), Shanghai, 201900, China

    Hua Xiao & Lei Shi

Authors
  1. Kaijun Lu
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Contributions

Kaijun Lu: conceptualization, methodology, experiments, writing—original draft.

Zhenye Liang: conceptualization, methodology, simulation, experiments, writing—original draft.

Tianxia Zou: resources, funding acquisition.

Yongkai Wang: simulation.

Dayong Li: resources, funding acquisition, conceptualization, writing—review and editing, supervision.

Shichao Ding: conceptualization, methodology.

Hua Xiao: resources, software, experiments.

Lei Shi: resources, software, experiments.

Yinghong Peng: resources, project administration.

Corresponding author

Correspondence to Dayong Li.

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Lu, K., Liang, Z., Zou, T. et al. On feasibility of roll-stamp forming variable-sectional metal channels. Int J Adv Manuf Technol 125, 319–340 (2023). https://doi.org/10.1007/s00170-022-10633-1

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  • DOI: https://doi.org/10.1007/s00170-022-10633-1

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