Forming Quality Analysis on the Cold Roll Forming C-channel Steel
Abstract
:1. Introduction
2. Materials and Methods
2.1. Experiment and Simulation Model Set Up
2.2. Residual Stress Measurement
3. Forming Passes Design and Analysis
4. Results and Discussion
4.1. Simulation Analysis of the Forming Process on the C-Channel Steel
4.2. Residual Stress Analysis on the C-Channel Steel
5. Conclusions
- (1)
- The forming quality of the bite zone is the worst in the whole cold roll forming process. The analysis of the layered distribution of sheet shows that the external layer is mainly subject to tensile stress, while the internal layer is mainly subject to compressive stress, and the internal layer residual stress is slightly larger than the external layer. It offers a reference for the forming of anisotropy material and the material with different coatings at internal and external surfaces.
- (2)
- The equations for calculating forming passes that are proposed by many scholars are based on the materials and shapes of the products they studied and lack of universality. They can only predict the number of forming passes roughly and verified by experience.
- (3)
- In order to save costs, one forming pass can be used to shaping the short edge of the target product (such as Section 1 in Figure 2a 3 mm short edge in this paper). However, the forming shape and dimension accuracy are not very good. This design method is suitable for those products that do not require high quality at the short edges. For the high quality and accuracy dimension products, more forming passes are needed for the short edge forming.
- (4)
- For long edge forming of the target product (such as Section 3 in Figure 2a 19 mm long edge), several forming passes (seven passes are used in this paper) are needed to avoid the dangerous area and keep the dimension accuracy. An over bending pass is needed to compensate the material springback, especially in the long edge forming.
- (5)
- The forming process in this paper offers a reference for the forming pass design of U-channel and V-channel steel.
- (6)
- Residual stress measurement of C-channel steel shows that the external surface of C-channel steel is mainly tensile stress, the internal surface is mainly compressive stress, and the residual stress of flange is far greater than that of web zone, which hardly deforms during cold roll forming and residual stress is very small.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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C | S | Si | Mn | P |
---|---|---|---|---|
0.150 | 0.035 | 0.300 | 0.350 | 0.035 |
Yield Strength (MPa) | Tensile Strength (MPa) | Elongation (%) |
---|---|---|
235 | 423 | 26 |
Parameter | Value |
---|---|
Bragg crystal angle | 82.33° |
Crystal surface | 211 |
Wavelength | 1.54 angstrom |
Light seams | 1 mm |
Calculation Method | Number of Forming Passes |
---|---|
Equation (4) | 10 |
Equation (5) | 14 |
Equation (6) | 9 |
Equation (7) | 8 |
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Hui, X.; Wang, X. Forming Quality Analysis on the Cold Roll Forming C-channel Steel. Materials 2018, 11, 1911. https://doi.org/10.3390/ma11101911
Hui X, Wang X. Forming Quality Analysis on the Cold Roll Forming C-channel Steel. Materials. 2018; 11(10):1911. https://doi.org/10.3390/ma11101911
Chicago/Turabian StyleHui, Xiangjun, and Xianming Wang. 2018. "Forming Quality Analysis on the Cold Roll Forming C-channel Steel" Materials 11, no. 10: 1911. https://doi.org/10.3390/ma11101911
APA StyleHui, X., & Wang, X. (2018). Forming Quality Analysis on the Cold Roll Forming C-channel Steel. Materials, 11(10), 1911. https://doi.org/10.3390/ma11101911