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Prototyping of straight section components using incremental shape rolling

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Abstract

Flexible Roll Forming (FRF) allows the forming of components with a variable cross section along the length of the component. However, the process has only limited application in the automotive industry due to wrinkling in the flange which currently prevents the forming of high strength steels and limits the part shape complexity. This paper presents a new forming technology, Incremental Shape Rolling (ISR), where a pre-cut blank is clamped between two dies, and then a single forming roll is used to incrementally form the material to the desired shape. The new process is similar to some Incremental Sheet Forming (ISF) approaches but with the difference that Incremental Shape Rolling (ISR) allows the manufacture of longitudinal components from high strength metal sheets. In this work, a numerical model of the ISR of a straight section is developed. Experimental prototyping trials are performed and are used to validate the numerical model which is then applied to analyse the new forming process. The results show that in ISR, tensile residual strains are developed in the flange. Flange wrinkling is observed and directly linked to the number of forming passes that are used in the process.

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Acknowledgements

The authors acknowledge data M Sheet Metal Solutions GmbH for the development and manufacture of the 3D roll forming prototyping facility.

Funding

The authors would like to thank Deakin University Postgraduate Research Scholarships (DUPRS) for the financial support.

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Authors and Affiliations

  1. Institute for Frontier Materials, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC, 3216, Australia

    Abdelrahman Essa, Buddhika Abeyrathna & Matthias Weiss

  2. School of Mechanical Engineering, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC, 3216, Australia

    Bernard Rolfe

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  1. Abdelrahman Essa
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  2. Buddhika Abeyrathna
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  3. Bernard Rolfe
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Correspondence to Abdelrahman Essa.

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Appendix

Appendix

Mesh sensitivity analysis has been done, where the flange has been modelled with four sizes of the mesh element. That is, 1: 1.5 × 1, 2: 1.1 × 1, 3: 1.1 × 0.8 and 4: 1 × 0.8 mm along the Z-direction and X-direction, respectively, see Fig. 10b. Figures 24 and 25 show the FEA results of the stainless steel profile after the final forming pass of the 12-step forming condition. The max X deviation has been chosen for the mesh sensitivity analysis investigation as it is an independent parameter, while f intact depends on the magnitude of max X deviation. That is, the higher X deviation the smaller would be f intact. The FEA result of the max. X deviation has converged at a mesh size of 3: 1.1 × 0.8 mm along the blank length and width, respectively, see Fig. 24.

Fig. 24
figure 24

The FEA results of the predicted max. X deviation for the different element sizes

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Fig. 25
figure 25

Equivalent plastic strain results; (a) mesh size 1, (b) mesh size 4 and (c) the maximum equivalent plastic strain as a function of mesh size

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To determine the extent of the plastic deformation along the flange, the equivalent plastic strain PEEQ has been investigated at the outer surface of the stainless steel profile. A PEEQ value higher than zero in the flange zone means that the flange has been exposed to plastic deformation. Figure 25a, b shows the PEEQ distribution for the two extreme mesh sizes. This clearly shows that the distribution of the equivalent plastic strain is almost similar with the max PEEQ occurring just under the profile radius and reducing to zero at the flange edge. As shown in Fig. 25c, the max PEEQ increases with decreasing mesh size and converges at a mesh size of 3: 1.1 × 0.8 mm along the blank length and width, respectively.

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Essa, A., Abeyrathna, B., Rolfe, B. et al. Prototyping of straight section components using incremental shape rolling. Int J Adv Manuf Technol 121, 3883–3901 (2022). https://doi.org/10.1007/s00170-022-09600-7

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  • DOI: https://doi.org/10.1007/s00170-022-09600-7

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