Experimental study into the correlation between the incremental forming and the nature of springback in automotive steels

Bending in a V-die has been well covered in the literature and the results have been used to indicate the out-come of bending in cold roll forming. However, recent work comparing springback between roll forming and single step bending has found lower springback in the roll forming process compared to single step bending. Roll forming is an incremental bending process and in this study a V-section was formed in a single operation and in multiple steps and the springback determined. The springback in V-die forming was significantly reduced by incremental forming. This suggests that the lower springback determined in roll forming compared to single step bending may be related to the incremental nature of the roll forming process.

Theoretical extension of elastic-perfectly plastic deformation length in roll forming of a channel section

In this paper, the Young’s modulus and the yield strength of the strip are considered in order to modify the deformation length analysis proposed by Bhattacharyya et al. New analytical equations are developed assuming an elastic-perfectly plastic material behaviour and the deformation length analysed for the simple case of roll forming a U-channel; the analytical results are verified by comparison with experimental data found in the literature. The proposed elastic-plastic deformation length is shorter than Bhattacharyya’s which is rigid-perfectly plastic. It is observed that the influence of elastic properties on the deformation length is not as significant as the plastic properties; however, the authors believe that the elastic effects become more important under conditions where a major area of the strip is under elastic deformation such as when the flange length is long.

An experimental investigation of edge strain and bow in roll forming a V-section

V-sections were roll formed from two grades of steel, and the strain on the top and bottom of the strip near the edge was measured using electrical resistance strain gauges. The channels were bent to a radius of 2 and 15 mm along the centerline. The steel strips were of mild and dual phase steel of yield strength 367 MPa and 597 MPa respectively. The longitudinal bow was measured using a 3-dimensional scanning system. The strain measurements were analysed to determine bending and mid-surface strains at the edge during forming. The peak longitudinal edge strain increased with material yield strength for both profile radii. For the 15 mm radius, the bow was larger in the dual phase steel than in the mild steel. For the 2 mm profile radius, the bow was smaller compared with the 15 mm profile radius and it was similar for both steels. It was observed that the difference between the peak longitudinal edge strain and yield strength to Youngs modulus ratio of the material is an important factor in determining longitudinal bow.