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Deformation length in flexible roll forming

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Abstract

Flexible roll forming (FRF) is a novel sheet metal process for innovative manufacturing of variable cross-section profiles which are especially needed in the automotive industry to construct lightweight structures. One of the important parameters of the flexible roll forming process is deformation length which plays a key role in the design of interstand distance. This paper presents a new understanding on the deformation length in the flexible roll forming process by performing experimental tests and numerical simulations. Results show that in flexible roll forming, unlike conventional roll forming, the deformation length varies considerably in such a way that the maximum and minimum values of the deformation length appear in the stretching and compression zones, respectively. Hence, it is recommended that the deformation length in the stretching zone is considered for designing the interdistance of stands. Results also allow concluding that the increase of the forming angle \(\alpha\), flange length \(F\), and yield strength \(Y\) and the decrease of thickness \(t\) increase the deformation length in all the regions of a variable cross-section profile.

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Acknowledgements

Mohammad Mehdi Kasaei gratefully acknowledges the funding provided by Operation NORTE-06-3559-FSE-000107–Contratação de Recursos Humanos Altamente Qualificados (PME ou CoLAB), supported by Norte 2020 through Fundo Social Europeu. The authors would like to acknowledge the support provided by Tarbiat Modares University.

Funding

The present research work was financially supported by Tarbiat Modares University. This study was also funded by Operation NORTE-06–3559-FSE-000107–Contratação de Recursos Humanos Altamente Qualificados (PME ou CoLAB), supported by Norte 2020 through Fundo Social Europeu.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran

    Hassan Badparva, Hassan Moslemi Naeini & Behnam Abbaszadeh

  2. Institute of Science and Innovation in Mechanical and Industrial Engineering, Porto, Portugal

    Mohammad Mehdi Kasaei

  3. Department of Mechanical Engineering, Qazvin Branch, Islamic Azad University, Qazvin, Iran

    Mohammad Mehdi Kasaei

  4. Department of Mechanical Engineering, Tehran Branch, Faculty of Enghelab-E Eslami, Technical and Vocational University, Tehran, Iran

    Yaghoub Dadgar Asl

  5. Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Porto, Portugal

    Lucas F. M. da Silva

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  1. Hassan Badparva
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  2. Hassan Moslemi Naeini
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  3. Mohammad Mehdi Kasaei
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  4. Yaghoub Dadgar Asl
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  5. Behnam Abbaszadeh
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  6. Lucas F. M. da Silva
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Correspondence to Mohammad Mehdi Kasaei.

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Badparva, H., Naeini, H.M., Kasaei, M.M. et al. Deformation length in flexible roll forming. Int J Adv Manuf Technol 125, 1229–1238 (2023). https://doi.org/10.1007/s00170-023-10803-9

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  • DOI: https://doi.org/10.1007/s00170-023-10803-9

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