An extension of the flower pattern diagram for roll forming

The initial process design of a roll forming system is often based on the traditional ‘flower pattern diagram’. In this diagram, the cross sections of the strip at each roll stand are superimposed on a single plane; the diagram is a 2D representation of the 3D process. In the present work, the flower pattern is extended into three dimensions. To demonstrate the method, the forming path or trajectory of a point at the edge of the strip during forming a V-section is considered. The forming path is a surface curve that lies on a cylindrical surface having its axis along the machine axis. This surface is unwrapped to give its plane development and important features of the forming process can be determined and are readily interpreted from this plane curve. It is shown that at any stage in the process, the axial strain and the curvature of the sheet adjacent to the point are dependent on the slope of the trajectory in this plane projection. This new diagram, which apparently has not been used previously, provides a useful initial method of examining the roll forming process and optimising the flower pattern. The model is purely geometric, as is the original flower pattern approach, and does not include the effect of material behaviour. The concept is applied to several cases available in the literature. It shows that the lowest level of shape defect in the part is achieved when the trajectory of the strip edge follows the shortest line length between the start and finish of forming, leading to the least longitudinal strain introduced in the flange. This trend is in agreement with previous experimental observations, suggesting that the analytical model proposed may be applied for early process design and optimisation before time-consuming numerical analysis is performed.

Numerical modeling and analysis for forming process of dual-phase 980 steel exposed to infrared local heating

A recent experiment confirmed that the infrared (IR) local heating method drastically reduces springback of dual-phase (DP) 980 sheets. In the experiment, only the plastic deformation zone of the sheets was locally heated using condensed IR heating. The heated sheets were then deformed by V-bending or 2D-draw bending. Although the experimental observation proved the merit of using the IR local heating to reduce springback, numerical modeling has not been reported. Numerical modeling has been required to predict springback and improve the understanding of the forming process. This paper presents a numerical modeling for V-bending and 2D-draw bending of DP 980 sheets exposed to the IR local heating with the finite element method (FEM). For describing the thermo-mechanical behavior of the DP 980 sheet, a flow stress model which includes a function of temperature and effective plastic strain was newly implemented into Euler-backward stress integration method. The numerical analysis shows that the IR local heating reduces the level of stress in the deformation zone, although it heats only the limited areas, and then it reduces the springback. The simulation also provides a support that the local heating method has an advantage of shape accuracy over the method to heat the material as a whole in V-bending. The simulated results of the springback in both V-bending and 2D-draw bending also show good predictions.

Forests of the sea: predictive habitat modelling to assess the abundance of canopy forming kelp forests on temperate reefs

 Large brown seaweeds (kelps) form forests in temperate and boreal marine systems that serve as foundations to the structure and dynamics of communities. Mapping the distributions of these species is important to understanding the ecology of coastal environments, managing marine ecosystems (e.g., spatial planning), predicting consequences of climate change and the potential for carbon production. We demonstrate how combining seafloor mapping technologies (LiDAR and multibeam bathymetry) and models of wave energy to map the distribution and relative abundance of seaweed forests of Ecklonia radiata can provide complete coverage over hundreds of square kilometers. Using generalized linear mixed models (GLMMs), we associated observations of E. radiata abundance from video transects with environmental variables. These relationships were then used to predict the distribution of E. radiata across our 756.1km2 study area off the coast of Victoria, Australia. A reserved dataset was used to test the accuracy of these predictions. We found that the abundance distribution of E. radiata is strongly associated with depth, presence of rocky reef, curvature of the reef topography, and wave exposure. In addition, the GLMM methodology allowed us to adequately account for spatial autocorrelation in our sampling methods. The predictive distribution map created from the best GLMM predicted the abundance of E. radiata with an accuracy of 72%. The combination of LiDAR and multibeam bathymetry allowed us to model and predict E. radiata abundance distribution across its entire depth range for this study area. Using methods like those presented in this study, we can map the distribution of macroalgae species, which will give insight into ecological communities, biodiversity distribution, carbon uptake, and potential sequestration.

The influence of residual stress on a roll forming process

Roll forming is increasingly used in the automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for structural components. Because of the large variety of applications of roll forming in the industry, Finite Element Analysis (FEA) is increasingly utilized for roll forming process design. Bending is the dominant deformation mode in roll forming and sheet materials used in the process are often temper rolled (skin passed), roller- or tension-levelled. These processes introduce residual stresses into the material, and recent studies have shown that those affect the material behaviour in bending. A thickness reduction rolling process available at Deakin that leads to material deformation similar to an industrial temper rolling operation was used in this study to introduce residual stresses into a dual phase, DP780, steel strip. The initial and thickness reduced strips were then used in a 5-stand experimental V-section roll forming set-up to identify the effect of residual stress on the final shape. The influence of residual stress and the effect of plastic deformation on the material behaviour in roll forming are separately determined in numerical simulation. The results show that the thickness reduction rolling process decreases the maximum bow height while the springback angle and end flare increase. Comparison with experimental results shows that using material data from the conventional tensile test in a numerical simulation does not allow for the accurate prediction of shape defects in a roll forming process if a residual stress profile exists in the material. On the other hand including the residual stress information leads to improved model accuracy.