Roll forming cryo-rolled nano-structured aluminium sheet

Commercial purity aluminium plate was reduced by rolling under nitrogen in 30 passes from an initial material thickness of 10 mm to a final thickness of 2 mm (80% reduction). Analysis of the microstructure showed that the material produced in this way had an ul-trafine grained microstructure. The sheet was roll formed at room temperature to a V-section using commercial roll forming equipment. Two sets of experiments were per-formed; one with a 15 mm radius in the base of the V and the other with a 5 mm radius. The performance in terms of final shape and springback is compared with the same part shape formed by V-die bending. The mechanical properties of the sheet were determined using the tensile test. It has been found that even if the total tensile elongation is close to zero and bending of the material is very limited, ultra-fine grained and low ductile sheet metals can be roll formed to simple section shapes.

Approach for testing the material behavior in roll forming in a small scale

Roll forming of ultra-high strength steels (UHSS) and other high strength alloys is an advanced manufacturing methodology with the ability of cold forming those materials to complex three-dimensional shapes for lightweight structural applications. Due to their high strength, most of these materials have a reduced ductility which excludes conventional sheet forming methods under cold forming conditions. Roll forming is possible due to its low strains and incremental forming characteristic. Recent research investigates the development of high strength nano-structured aluminum sheet and titanium alloys, as well as their behaviour in roll forming with regard to formability, material behaviour and shape defects. The development of new materials is often limited to small scale samples due to the high preparation costs. In contrast, industrial application needs larger scale tests for validation, especially in roll forming where a minimum sheet length is required to feed the sample trough the roll forming machine. This work describes a novel technique for studying roll forming of a short length of experimental material. DP780 steel strips (500mm – 1300mm length) were welded between two mild steel carrier sheets of similar width and thickness giving an overall strip length of 2m. Roll forming trials were performed and longitudinal edge strain, bow and springback determined on the welded samples and samples formed of full length DP780 strip before and after cut off. The experimental results of this work show that this method gives a reasonable approach for predicting material behavior in roll forming transverse to the rolling direction. In contrast to that significant differences in longitudinal bow were observed between the welded sections and the sections formed of full length DP780 strip; this indicates that the applicability of this method is limited with regard to predicting longitudinal material behavior in roll forming.

Distribution, extent of inter-annual variability and diet of the bloom-forming jellyfish Rhizostoma in European waters

Jellyfish (Cnidaria: Scyphozoa) are increasingly thought to play a number of important ecosystem roles, but often fundamental knowledge of their distribution, seasonality and inter-annual variability is lacking. Bloom forming species, due to their high densities, can have particularly intense trophic and socio-economic impacts. In northern Europe it is known that one particularly large (up to 30 kg wet weight) bloom forming jellyfish is Rhizostoma spp. Given the potential importance, we set out to review all known records from peer-reviewed and broader public literature of the jellyfish R. octopus (Linnaeus) and R. pulmo (Macri) (Scyphozoa: Rhizostomae) across western Europe. These data revealed distinct hotspots where regular Rhizostoma spp. aggregations appeared to form, with other sites characterized by occasional abundances and a widespread distribution of infrequent observations. Surveys of known R. octopus hotspots around the Irish Sea also revealed marked inter-annual variation with particularly high abundances forming during 2003. The location of such consistent aggregations and inter-annual variances are discussed in relation to physical, climatic and dietary variations.

Using the solid-shell element to model the roll forming of large radii profiles

Roll forming is an incremental bending process for forming metal sheet, strip or coiled stock. Although Finite Element Analysis (FEA) is a standard tool for metal forming simulation, it is only now being increasingly used for the analysis of the roll forming process. This is because of the excessive computational time due to the long strip length and the multiple numbers of stands that have to be modelled. Typically a single solid element is used through the thickness of the sheet for roll forming simulations. Recent investigations have shown that residual stresses introduced during steel processing may affect the roll forming process and therefore need to be included in roll forming simulations. These residual stresses vary in intensity through the thickness and this cannot be accounted for by using only one solid element through the material thickness, in this work a solid-shell element with an arbitrary number of integration points has been used to simulate the roll forming process. The system modelled is that of roll forming a V-channel with dual phase DP780 sheet steel. In addition, the influence of other modelling parameters, such as friction, on CPU time is further investigated. The numerical results are compared to experimental data and a good correlation has been observed. Additionally the numerical results show that the CPU time is reduced in the model without friction and that considering friction does not have a significant effect on springback prediction in the numerical analysis of the roll forming process.

One-size-fits-all housing : an exploration of 6-star requirements in the volume builder sector

Energy consumption attributed to the residential sector makes up around 8% of the total consumption in Australia. Roughly a third of all houses built in Victoria are done so by the largest 20 builders. These volume builders keep costs down by offering a selection of ‘clone’ designs from which the client can choose, however they lose the site-specific customisation which is required for effective passive design in favour of a one-size-fits-all approach where designs are developed to a point where they can satisfy just the minimum requirements in a range of orientations and site locations. The Australian government has implemented regulations regarding the minimum efficiency standards for housing and these initiatives to limit the carbon emissions have brought the question of energy use to the table, yet are they enough? This paper will explore the concept of cloned house designs in terms of energy efficiency and optimal siting and through computer simulation, evaluate how a cloned house design performs under different site conditions in Victoria.