Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component
Automotive structural components from Advanced High-Strength Steels (AHSS) can be manufactured with Flexible Roll Forming (FRF). The application of FRF in the automotive industry is limited due to flange wrinkling defects that increase with material strength. The new Incremental Shape Rolling proces...
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| Language: | English |
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MDPI AG
2024-12-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/8/6/290 |
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| author | Abdelrahman Essa Buddhika Abeyrathna Bernard Rolfe Matthias Weiss |
| author_facet | Abdelrahman Essa Buddhika Abeyrathna Bernard Rolfe Matthias Weiss |
| author_sort | Abdelrahman Essa |
| collection | DOAJ |
| description | Automotive structural components from Advanced High-Strength Steels (AHSS) can be manufactured with Flexible Roll Forming (FRF). The application of FRF in the automotive industry is limited due to flange wrinkling defects that increase with material strength. The new Incremental Shape Rolling process (ISR) has been shown to reduce wrinkling severity compared to FRF and therefore presents a promising alternative for the manufacture of high-strength automotive components. The current work analyzes for the first time the mechanisms that lead to wrinkling reduction in ISR based on the critical stress conditions that develop in the flange. For this, finite element process models are validated with experimental forming trials and used to investigate the material deformation and the forming stresses that occur in FRF and ISR when forming a variable-width automotive component. The results show that in ISR, the undeformed flange height decreases with increasing forming; this increases the critical buckling and wrinkling stresses with each forming pass and prevents the development of wrinkles towards the end of the forming process. In contrast, in FRF, the critical buckling or wrinkling stress is constant, while the longitudinal compressive stress in the flange increases with the number of forming passes and exceeds the critical stress. This leads to the development of severe wrinkles in the flange. |
| format | Article |
| id | doaj-art-9830d09e22f14a8b8d70f8b8f4e5581b |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-9830d09e22f14a8b8d70f8b8f4e5581b2024-12-27T14:32:54ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-12-018629010.3390/jmmp8060290Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width ComponentAbdelrahman Essa0Buddhika Abeyrathna1Bernard Rolfe2Matthias Weiss3Institute for Frontier Materials, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC 3216, AustraliaInstitute for Frontier Materials, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC 3216, AustraliaSchool of Mechanical Engineering, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC 3216, AustraliaInstitute for Frontier Materials, Deakin University, Waurn Ponds, Pigdons Rd., Geelong, VIC 3216, AustraliaAutomotive structural components from Advanced High-Strength Steels (AHSS) can be manufactured with Flexible Roll Forming (FRF). The application of FRF in the automotive industry is limited due to flange wrinkling defects that increase with material strength. The new Incremental Shape Rolling process (ISR) has been shown to reduce wrinkling severity compared to FRF and therefore presents a promising alternative for the manufacture of high-strength automotive components. The current work analyzes for the first time the mechanisms that lead to wrinkling reduction in ISR based on the critical stress conditions that develop in the flange. For this, finite element process models are validated with experimental forming trials and used to investigate the material deformation and the forming stresses that occur in FRF and ISR when forming a variable-width automotive component. The results show that in ISR, the undeformed flange height decreases with increasing forming; this increases the critical buckling and wrinkling stresses with each forming pass and prevents the development of wrinkles towards the end of the forming process. In contrast, in FRF, the critical buckling or wrinkling stress is constant, while the longitudinal compressive stress in the flange increases with the number of forming passes and exceeds the critical stress. This leads to the development of severe wrinkles in the flange.https://www.mdpi.com/2504-4494/8/6/290incremental shape rollingflexible roll formingfinite element modellingwrinkling |
| spellingShingle | Abdelrahman Essa Buddhika Abeyrathna Bernard Rolfe Matthias Weiss Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component Journal of Manufacturing and Materials Processing incremental shape rolling flexible roll forming finite element modelling wrinkling |
| title | Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component |
| title_full | Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component |
| title_fullStr | Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component |
| title_full_unstemmed | Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component |
| title_short | Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component |
| title_sort | flange buckling mechanism in incremental shape rolling of an automotive type variable width component |
| topic | incremental shape rolling flexible roll forming finite element modelling wrinkling |
| url | https://www.mdpi.com/2504-4494/8/6/290 |
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