Experimental Analysis of Effective Parameters on the Bowing Defect of Symmetrical U-Section in Roll Forming Production

الموضوعات :

Amin Poursafar ¹ , Saeid Saberi ² , Rasoul Tarkesh Esfahani ³ , Meisam Vahabi ⁴ , Javad Jafari Fesharaki ⁵

1 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran.
2 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran.
3 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran.
4 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najababad, Iran.
5 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran.

تاريخ الإرسال : 07 الإثنين , ذو القعدة, 1443 تاريخ التأكيد : 27 الأحد , ربيع الأول, 1444 تاريخ الإصدار : 07 الخميس , جمادى الأولى, 1444

الکلمات المفتاحية: bowing defect, Design of Experiments, symmetrical, roll forming, U- Section, Full factorial,

ملخص المقالة :

The roll forming process plays a critical role in producing various sections used in industries. Also, the quality of these products is strongly affected by the thickness of the strip, the distance between stands, the section web, the flower pattern, and the plastic anisotropy. Therefore, the influences of practical factors on the bowing defect of the symmetrical U-section are experimentally and mathematically characterized in the present research. The investigated material is DC03 (1.0347) steel. Different prediction models such as linear and non-linear model based on the general full-factorial design of experiment are used to predict the effect of following factors on the bowing defect. Accuracy of the analytical model was verified by comparing the output results with the practical data. Results show that the strip thickness of investigated material, the flower pattern, and the section web have the most significant effect on the bowing defect. Also, the anisotropic properties of the investigated material and the inter distance have the minor impact on the bowing defect, but the effect of material with considering the anisotropic properties on increasing the accuracy of process simulation results is very impressive and increases the accuracy of simulation results from 84% to 91%. Finally, the predicted bowing defect using the modified two-factor model was in 91% agreement with the experimental results.

المصادر:

• Halmos, G. T., Roll Forming Handbook, 2005. DOI: 10.1201/9781420030693.


• Shirani Bidabadi, B., Moslemi Naeini, H., Azizi Tafti, R., and Barghikar, H., Experimental Study of Bowing Defects in Pre-Notched Channel Section Products in The Cold Roll Forming Processint, J. Adv. Manuf. Technol., Vol. 87, No. 1–4, 2016, pp. 997–1011, DOI: 10.1007/s00170-016-8547-y.


• Ona, H., Experiments into the Cold Roll Forming of Straight Asymmetrical Channels, J. Mech. Work. Technol., Vol. 8, No. 83, 1983, pp. 273–291.


• Bhattacharyya, D., Smith, P. D., Thadakamalla, S. K., and Collins, I. F., The Prediction of Roll Load in Cold Roll-Forming, J. Mech. Work. Technol., Vol. 14, No. 3, 1987, pp. 363–379, DOI: 10.1016/0378-3804(87)90019-2.


• Bhattacharyya, D., Smith, P. D., The Development of Longitudinal Strain in Cold Roll Forming and Its Influence on Product Straightness, leAdv. Technol. Plast., Vol. 1, 1984, pp. 422–427.


• Panton, S., Duncan, J., and Zhu, S., Longitudinal and Shear Strain Development in Cold Roll Forming, J. Mater. Process. Technol., Vol. 60, 1996, pp. 219–224, DOI: 10.1016/0924-0136(96)02333-3.


• Sheu, J. J., Simulation and Optimization of The Cold Roll-Forming Process AIP Conf. Proc., Vol. 1, 2004, pp. 452–457, DOI: 10.1063/1.1766566.


• Tehrani, M. S., Hartley, P., Naeini, H. M., and Khademizadeh, H., Localised Edge Buckling in Cold Roll-Forming of Symmetric Channel Section Thin-Walled Struct., Vol. 44, No. 2, 2006, pp. 184–196, DOI: 10.1016/j.tws.2006.01.008.


• 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, J. Mater. Process. Technol., Vol. 225, 2015, pp. 213–220, DOI: 10.1016/j.jmatprotec.2015.06.008.


• Shirani Bidabadi, B., Moslemi Naeini, H., Salmani Tehrani, M., and Barghikar, H., Experimental and Numerical Study of Bowing Defects in Cold Roll-Formed, U-Channel Sections, J. Constr. Steel Res., Vol. 118, 2016, pp. 243–253, DOI: 10.1016/j.jcsr.2015.11.007.


• Shirani Bidabadi, B., Moslemi Naeini, H., Azizi Tafti, R., and Tajik, Y., Optimization of Required Torque and Energy Consumption in The Roll Forming Process, Int. J. Interact. Des. Manuf., Vol. 13, No. 3, 2019, pp. 1029–1048, DOI: 10.1007/s12008-019-00564-9.


• Lindgren, M., Cold Roll Forming of a U-Channel Made of High Strength Steel, J. Mater. Process. Technol., Vol. 186, No. 1–3, 2007, pp. 77–81, DOI: 10.1016/j.jmatprotec.2006.12.017.


• Poursina, M., Salmani Tehrani, M., and Poursina, D., Application of BPANN and Regression for Prediction of Bowing Defect in Roll-Forming of Symmetric Channel Section, Int. J. Mater. Form., Vol. 1, No. 1, 2008, pp. 17–20, DOI: 10.1007/s12289-008-0057-5.


• Bui, Q. V., Ponthot, J. P., Numerical Simulation of Cold Roll-Forming Processes, J. Mater. Process. Technol., Vol. 202, No. 1–3, 2008, pp. 275–282, DOI: 10.1016/j.jmatprotec.2007.08.073.


• Lindgren, M., An Improved Model for The Longitudinal Peak Strain in The Flange of a Roll Formed U-Channel Developed by FE-Analyses Steel Res. Int., Vol. 78, No. 1, 2007, pp. 82–87, DOI: 10.1002/srin.200705863.


• Wei Zhang, H., Zhong Liu, L., Hu, P., and Hua Liu, X., Numerical Simulation and Experimental Investigation of Springback in U-Channel Forming of Tailor Rolled Blank, J. Iron Steel Res. Int., Vol. 19, No. 9, 2012, pp. 8–12, DOI: 10.1016/S1006-706X(13)60002-3.


• Punin, V. I., Kokhan, L. S., and Morozov, Y. A., Reduction of the Length of Strip Rolled on Roll-Forming Machines Metallurgist, Vol. 56, No. 11–12, 2013, pp. 938–940, DOI: 10.1007/s11015-013-9678-0.


• Gi Cha, W., Kim, N., Study on Twisting and Bowing of Roll Formed Products Made of High Strength Steel, Int. J. Precis. Eng. Manuf., Vol. 14, No. 9, 2013, pp. 1527–1533, DOI: 10.1007/s12541-013-0206-8.


• Wiebenga, J. H., Weiss, M., Rolfe, B., and Van Den Boogaard, A. H., Product Defect Compensation by Robust Optimization of a Cold Roll Forming Process, J. Mater. Process. Technol., Vol. 213, No. 6, 2013, pp. 978–986, DOI: 10.1016/j.jmatprotec.2013.01.006.


• Safdarian, R., Moslemi Naeini, H.,The Effects of Forming Parameters on The Cold Roll Forming of Channel Section Thin-Walled Struct., Vol. 92, 2015, pp. 130–136, DOI: 10.1016/j.tws.2015.03.002.


• Shirani Bidabadi, B., Moslemi Naeini, H., Safdarian, R., and Barghikar, H., Investigation of Over-Bending Defect in The Cold Roll Forming of U-Channel Section Using Experimental and Numerical Methods, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., Vol. 236, No. 10, 2022, pp. 1380–1392, DOI: 10.1177/09544054221076628.


• Heydari Vini, M., Farhadipour, P., Fabrication of AA1060/Al2O3 Composites by Warm Accumulative Roll Bonding Process and Investigation of its Mechanical Properties and Microstructural Evolution ADMT J., Vol. 10, No. 4, 2017, pp. 91–98, [Online] Available: https://admt.majlesi.iau.ir/article_537192.html.


• Heydari, V. M., Saeed, D., Bonding Evolution of Bimetallic Al/Cu Laminates Fabricated by Asymmetric Roll Bonding, Adv. Mater. Res., Vol. 8, No. 1, 2019, pp. 1–10, DOI: 10.12989/AMR.2019.8.1.001.


• Sattar, S., Mazdak, S., and Sharifi, E., Numerical Analysis of Circular Pre-notched U-Channel Section Distortions in Cold Roll-Forming ProcessADMT J., Vol. 10, No. 2, 2017, pp. 121–131, [Online] Available: https://admt.majlesi.iau.ir/article_535020.html.


• Hill, R., Orowan, E., A Theory of the Yielding and Plastic Flow of Anisotropic Metals, Proc. R. Soc. London. Ser. A. Math. Phys. Sci., Vol. 193, No. 1033, 1948, pp. 281–297, DOI: 10.1098/rspa.1948.0045.


• Han, Z. W., Liu, C., Lu, W. P., and Ren, L. Q., Simulation of a Multi-Stand Roll-Forming Process for Thick Channel Section, J. Mater. Process. Technol., Vol. 127, No. 3, 2002, pp. 382–387, DOI: 10.1016/S0924-0136(02)00411-9.


• Mander, S. J., Panton, S. M., Dykes, R. J., and Bhattacharyya, D., Chapter 12 Roll Forming of Sheet Materials, in Composite Sheet Forming, Vol. 11, D. B. T. C. M. S. Bhattacharyya, Ed. Elsevier, 1997, pp. 473–515, DOI: https://doi.org/10.1016/S0927-0108(97)80014-8.