Skip to main content
Top

2022 | OriginalPaper | Chapter

5. Flexible 3D Profile Roll Forming Technology

Authors : Yong Sun, Albert Sedlmaier, Qiuquan Guo, Dongxing Zhang, Hui Xia, Shiyi Cu, Jie Dong, Yinwang Ren

Published in: Flexible Metal Forming Technologies

Publisher: Springer Nature Singapore

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Nowadays, roll forming becomes one of the most promising sheet metal forming method due to its excellent superiority of capital saving and capability of lightweight, high accuracy manufacturing technique. It has been increasingly used in a wide range of sectors, such as aerospace, automotive, transportation, construction, etc. However, with the requirements of rapid manufacturing and more complex customized profile shape in forming direction, such as variable shape, depth, etc., traditional roll forming is no longer suitable due to the movement restrictions along transverse and vertical directions. Also, with the trend of industry 4.0, traditional roll forming is fundamentally lack of machine learning capability for intelligent manufacturing upgrade. A new replacement called (3D) flexible roll forming has been proposed in recent years to confront the above challenges. The technology is carried out via an advanced control system. It is a complicated flexible manufacturing system composed of many key elements/parts, such as six-axis robot arms, high, blankholder system, smart sensors and other key elements.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Springer Professional "Wirtschaft"

Online-Abonnement

Mit Springer Professional "Wirtschaft" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 340 Zeitschriften

aus folgenden Fachgebieten:

  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Versicherung + Risiko




Jetzt Wissensvorsprung sichern!

Literature
1.
go back to reference Sedlmaier A, Ehrlenspiel K (1984) Integriertes computer-Programmsystem ”Kaltprofilierwalzen” (KPW). Fachberichte für Metallbearbeitung 61, No 11–12 Sedlmaier A, Ehrlenspiel K (1984) Integriertes computer-Programmsystem ”Kaltprofilierwalzen” (KPW). Fachberichte für Metallbearbeitung 61, No 11–12
2.
3.
go back to reference Sun Y (2017) Fundamental study of chain-die forming: identifying the essential characteristics of fabricated AHSS profiles enabling process improvement Sun Y (2017) Fundamental study of chain-die forming: identifying the essential characteristics of fabricated AHSS profiles enabling process improvement
4.
go back to reference Sedlmaier A, Dietl T, Ferreira P (2017) Digitalization in roll forming manufacturing. J Phys Conf Ser 896 Sedlmaier A, Dietl T, Ferreira P (2017) Digitalization in roll forming manufacturing. J Phys Conf Ser 896
5.
go back to reference Kasaei MM, Naeini HM, Abbaszadeh B, Silva MB, Martins PAF (2015) Flexible roll forming. In: Materials forming and machining, pp 51–71 Kasaei MM, Naeini HM, Abbaszadeh B, Silva MB, Martins PAF (2015) Flexible roll forming. In: Materials forming and machining, pp 51–71
6.
go back to reference Ma Y (2014) The control system research of multi-axis flexible roll forming. (Master), North China University of Technology Ma Y (2014) The control system research of multi-axis flexible roll forming. (Master), North China University of Technology
7.
go back to reference Sedlmaier A, Dietl T (2018) 3D roll forming center for automotive applications. Elsevier B.V, Procedia Manuf 15:767–774. In: 17th International conference on metal forming, metal forming, pp 16–19 Sedlmaier A, Dietl T (2018) 3D roll forming center for automotive applications. Elsevier B.V, Procedia Manuf 15:767–774. In: 17th International conference on metal forming, metal forming, pp 16–19
8.
go back to reference Sedlmaier A, Dietl T, Harrasser J (2017) 3D rollforming in automotive industry. In: SCT2017 5th international conference on steels for cars and trucks, steel institute. www.sct2017.com Sedlmaier A, Dietl T, Harrasser J (2017) 3D rollforming in automotive industry. In: SCT2017 5th international conference on steels for cars and trucks, steel institute. www.​sct2017.​com
9.
go back to reference Ai Z, Liu J, Han F, Jing Z (2010) Research improvement of variable section flexible roll forming technology at home and abroad. Automob Parts (19):34–36 Ai Z, Liu J, Han F, Jing Z (2010) Research improvement of variable section flexible roll forming technology at home and abroad. Automob Parts (19):34–36
10.
go back to reference Larrañaga J, Galdos L, Uncilla L, Etxaleku A (2010) Development and validation of a numerical model for sheet metal roll forming. IntJ Mater Form 3(1):151–154CrossRef Larrañaga J, Galdos L, Uncilla L, Etxaleku A (2010) Development and validation of a numerical model for sheet metal roll forming. IntJ Mater Form 3(1):151–154CrossRef
11.
go back to reference Sheu J-J, Liang C-F, Yu C-H, Hsu W-C, Lee P-K (2018) Flexible roll forming of U-section product with curved bending profile using advanced high strength steel. Procedia Manuf 15:782–787CrossRef Sheu J-J, Liang C-F, Yu C-H, Hsu W-C, Lee P-K (2018) Flexible roll forming of U-section product with curved bending profile using advanced high strength steel. Procedia Manuf 15:782–787CrossRef
12.
go back to reference Dr & Prof (2018) Key technology and development of roll forming in automobile lightweight—North China University of Technology. In: Proceedings of the first automobile internal high pressure forming and high strength steel and aluminum forming technology forum, pp 35–44 Dr & Prof (2018) Key technology and development of roll forming in automobile lightweight—North China University of Technology. In: Proceedings of the first automobile internal high pressure forming and high strength steel and aluminum forming technology forum, pp 35–44
13.
go back to reference Park HS, Dang DV, Nguyen TT (2019) Development of a flexible roll forming machine for cutting cured parts with virtual prototyping technology Park HS, Dang DV, Nguyen TT (2019) Development of a flexible roll forming machine for cutting cured parts with virtual prototyping technology
14.
go back to reference Buddhika Abeyrathna DMW, A/Prof Bernard Rolfe (2018) WISCO interim report_27_08_2018_Final Buddhika Abeyrathna DMW, A/Prof Bernard Rolfe (2018) WISCO interim report_27_08_2018_Final
15.
go back to reference Jiao J, Rolfe B, Mendiguren J, Weiss M (2015) An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width. Int J Mech Sci 90:228–238CrossRef Jiao J, Rolfe B, Mendiguren J, Weiss M (2015) An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width. Int J Mech Sci 90:228–238CrossRef
16.
go back to reference Sedlmaier A, Dietl T (2018) 3D roll forming center for automotive applications. Elsevier B.V. Procedia Manuf 15:767–774CrossRef Sedlmaier A, Dietl T (2018) 3D roll forming center for automotive applications. Elsevier B.V. Procedia Manuf 15:767–774CrossRef
17.
go back to reference Yan Y, Wang H, Li Q, Qian B, Mpofu K (2014) Simulation and experimental verification of flexible roll forming of steel sheets. Int J Adv Manuf Technol 72(1–4):209–220CrossRef Yan Y, Wang H, Li Q, Qian B, Mpofu K (2014) Simulation and experimental verification of flexible roll forming of steel sheets. Int J Adv Manuf Technol 72(1–4):209–220CrossRef
18.
go back to reference Weiss M (2019) Confirmation of candidature report Weiss M (2019) Confirmation of candidature report
19.
go back to reference Sreenivas AA (2020) Confirmation of candidature report Sreenivas AA (2020) Confirmation of candidature report
20.
go back to reference Yong Sun DBA, Weiss M, Peirra M (2017) Deakin University and Wuhan Iron and Steel (Group) Corp. Yong Sun DBA, Weiss M, Peirra M (2017) Deakin University and Wuhan Iron and Steel (Group) Corp.
21.
go back to reference Weibiao C, Shuanhu W, Binbin P, Yu S (2013) Aided design of P form tube by COPRA. Mach Tool Hydraul 41(05):85–88 Weibiao C, Shuanhu W, Binbin P, Yu S (2013) Aided design of P form tube by COPRA. Mach Tool Hydraul 41(05):85–88
22.
go back to reference Zhenxi L, Tingyu Z, Jianpin L, Yu Q (2019) Roll forming process design and FEM analysis of automobile anti-collision beam based on COPRA. Paper presented at the The 15th China CAE engineering analysis technology annual conference, Shanghai, China Zhenxi L, Tingyu Z, Jianpin L, Yu Q (2019) Roll forming process design and FEM analysis of automobile anti-collision beam based on COPRA. Paper presented at the The 15th China CAE engineering analysis technology annual conference, Shanghai, China
23.
go back to reference Qing-dong S, Chuan-hong W, You-liang R, Liang G, Peng J (2016) T-tube forming process optimization and the rolling die design based on COPRA. Die Mould Ind 42(09):59–63 Qing-dong S, Chuan-hong W, You-liang R, Liang G, Peng J (2016) T-tube forming process optimization and the rolling die design based on COPRA. Die Mould Ind 42(09):59–63
24.
go back to reference Deole AD, Design ME (2019) Thesis_Final_weiss Deole AD, Design ME (2019) Thesis_Final_weiss
25.
go back to reference Bao Z, Wuxue D, Binbin P (2014) Application of downhill method in roll forming. Forging Stamping Technol 39(01):52–57 Bao Z, Wuxue D, Binbin P (2014) Application of downhill method in roll forming. Forging Stamping Technol 39(01):52–57
26.
go back to reference Abeyrathna B, Abvabi A, Rolfe B, Taube R, Weiss M (2016) Numerical analysis of the flexible roll forming of an automotive component from high strength steel. IOP Conf Ser Mater Sci Eng 159(1):012005 (012009pp) Abeyrathna B, Abvabi A, Rolfe B, Taube R, Weiss M (2016) Numerical analysis of the flexible roll forming of an automotive component from high strength steel. IOP Conf Ser Mater Sci Eng 159(1):012005 (012009pp)
27.
go back to reference BAJC&Fund (2019) Baosteel 2019_Weiss_160719_Final (2) BAJC&Fund (2019) Baosteel 2019_Weiss_160719_Final (2)
28.
go back to reference Abeyrathna B, Rolfe B, Harrasser J, Sedlmaier A, Ge R, Pan L, Weiss M (2017) Prototyping of automotive components with variable width and depth. J Phys Conf Ser 896 Abeyrathna B, Rolfe B, Harrasser J, Sedlmaier A, Ge R, Pan L, Weiss M (2017) Prototyping of automotive components with variable width and depth. J Phys Conf Ser 896
29.
go back to reference Eggertsen PA, Mattiasson K (2009) On the modelling of the bending–unbending behaviour for accurate springback predictions. Int J Mech Sci 51(7):547–563CrossRef Eggertsen PA, Mattiasson K (2009) On the modelling of the bending–unbending behaviour for accurate springback predictions. Int J Mech Sci 51(7):547–563CrossRef
30.
go back to reference Kim D, Lee M-G, Kim C, Wenner ML, Wagoner RH, Barlat F, Kang TJ (2003) Measurements of anisotropic yielding, bauschinger and transient behavior of automotive dual-phase steel sheets. Met Mater Int 9(6):561CrossRef Kim D, Lee M-G, Kim C, Wenner ML, Wagoner RH, Barlat F, Kang TJ (2003) Measurements of anisotropic yielding, bauschinger and transient behavior of automotive dual-phase steel sheets. Met Mater Int 9(6):561CrossRef
31.
go back to reference Li Y, Sun Y (2018) A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming. Int J Mech Sci Li Y, Sun Y (2018) A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming. Int J Mech Sci
32.
go back to reference Morestin F, Boivin M (1996) On the necessity of taking into account the variation in the Young modulus with plastic strain in elastic-plastic software. Nucl Eng Des 162(1):107–116CrossRef Morestin F, Boivin M (1996) On the necessity of taking into account the variation in the Young modulus with plastic strain in elastic-plastic software. Nucl Eng Des 162(1):107–116CrossRef
33.
go back to reference PÉRez R, Benito J, Prado J (2005) Study of the inelastic response of TRIP steels after plastic deformation. Isij International—ISIJ INT 45:1925–1933 PÉRez R, Benito J, Prado J (2005) Study of the inelastic response of TRIP steels after plastic deformation. Isij International—ISIJ INT 45:1925–1933
34.
go back to reference Yu HY (2009) Variation of elastic modulus during plastic deformation and its influence on springback. Mater Des 30(3):846–850CrossRef Yu HY (2009) Variation of elastic modulus during plastic deformation and its influence on springback. Mater Des 30(3):846–850CrossRef
35.
go back to reference Weiss M, Wolfkamp H, Rolfe BF, Hodgson PD, Hemmerich E (2009) Measurement of bending properties in strip for roll forming Weiss M, Wolfkamp H, Rolfe BF, Hodgson PD, Hemmerich E (2009) Measurement of bending properties in strip for roll forming
36.
go back to reference Woo YY, Han SW, Hwang TW, Park JY, Moon YH (2018) Characterization of the longitudinal bow during flexible roll forming of steel sheets. J Mater Process Technol 252:782–794CrossRef Woo YY, Han SW, Hwang TW, Park JY, Moon YH (2018) Characterization of the longitudinal bow during flexible roll forming of steel sheets. J Mater Process Technol 252:782–794CrossRef
37.
go back to reference Abeyrathna B, Ghanei S, Rolfe B, Taube R, Weiss M (2021) Optimising part quality in the flexible roll forming of an automotive component. Int J Adv Manuf Technol, 1–13 Abeyrathna B, Ghanei S, Rolfe B, Taube R, Weiss M (2021) Optimising part quality in the flexible roll forming of an automotive component. Int J Adv Manuf Technol, 1–13
38.
go back to reference Kang PG, Woo YY, Moon YH (2018) Effects of circular holes on the web warping of perforated blanks in flexible roll forming. Proc Inst Mech Eng Part B J Eng Manuf 233(9):1980–1992CrossRef Kang PG, Woo YY, Moon YH (2018) Effects of circular holes on the web warping of perforated blanks in flexible roll forming. Proc Inst Mech Eng Part B J Eng Manuf 233(9):1980–1992CrossRef
39.
go back to reference Larrañaga J, Berner S, Galdos L, Groche P, Chinesta F, Chastel Y, El Mansori M (2011) Geometrical accuracy improvement in flexible roll forming lines Larrañaga J, Berner S, Galdos L, Groche P, Chinesta F, Chastel Y, El Mansori M (2011) Geometrical accuracy improvement in flexible roll forming lines
40.
go back to reference Park J-C, Yang D-Y, Cha M, Kim D, Nam J-B (2014) Investigation of a new incremental counter forming in flexible roll forming to manufacture accurate profiles with variable cross-sections. Int J Mach Tools Manuf 86:68–80CrossRef Park J-C, Yang D-Y, Cha M, Kim D, Nam J-B (2014) Investigation of a new incremental counter forming in flexible roll forming to manufacture accurate profiles with variable cross-sections. Int J Mach Tools Manuf 86:68–80CrossRef
41.
go back to reference Weiss M (2020) Combined_CoC_Report-2_Weiss 3(1) Weiss M (2020) Combined_CoC_Report-2_Weiss 3(1)
42.
go back to reference Kasaei MM, Naeini HM, Liaghat GH, Silva CMA, Silva MB, Martins PAF (2015) Revisiting the wrinkling limits in flexible roll forming. J Strain Anal Eng Des 50(7):528–541CrossRef Kasaei MM, Naeini HM, Liaghat GH, Silva CMA, Silva MB, Martins PAF (2015) Revisiting the wrinkling limits in flexible roll forming. J Strain Anal Eng Des 50(7):528–541CrossRef
43.
go back to reference Groche P, Zettler A, Berner S, Schneider G (2011) Development and verification of a one-step-model for the design of flexible roll formed parts. IntJ Mater Form 4(4):371–377CrossRef Groche P, Zettler A, Berner S, Schneider G (2011) Development and verification of a one-step-model for the design of flexible roll formed parts. IntJ Mater Form 4(4):371–377CrossRef
44.
go back to reference Abee A, Berner S, Sedlmaier A (2008) Accuracy improvement of roll formed profiles with variable cross sections. 기타자료, 249–250 Abee A, Berner S, Sedlmaier A (2008) Accuracy improvement of roll formed profiles with variable cross sections. 기타자료, 249–250
45.
go back to reference Abeyrathna B, Rolfe B, Pan L, Ge R, Weiss M (2016) Flexible roll forming of an automotive component with variable depth. Adv Mater Process Technol 2(4):527–538 Abeyrathna B, Rolfe B, Pan L, Ge R, Weiss M (2016) Flexible roll forming of an automotive component with variable depth. Adv Mater Process Technol 2(4):527–538
46.
go back to reference Abeyrathna B, Ghanei S, Rolfe B, Taube R, Weiss M .(2020) Springback and end flare compensation in flexible roll forming Abeyrathna B, Ghanei S, Rolfe B, Taube R, Weiss M .(2020) Springback and end flare compensation in flexible roll forming
47.
go back to reference Yan Y, Nie H, Wang H, Li Q, Liu Y (2017) A novel roll-die forming technology and its FEM simulation Yan Y, Nie H, Wang H, Li Q, Liu Y (2017) A novel roll-die forming technology and its FEM simulation
48.
go back to reference Weiss M, Buddhika A, Sadegh G, Bernard R, Richard T (2021) Optimising part quality in the flexible roll forming of an automotive component Weiss M, Buddhika A, Sadegh G, Bernard R, Richard T (2021) Optimising part quality in the flexible roll forming of an automotive component
49.
go back to reference Yu Y, Wang H, Li Q, Guan Y (2015) Finite element simulation of flexible roll forming with supplemented material data and the experimental verification Yu Y, Wang H, Li Q, Guan Y (2015) Finite element simulation of flexible roll forming with supplemented material data and the experimental verification
50.
go back to reference Kasaei MM, Naeini HM, Abbaszadeh B, Mohammadi M, Ghodsi M, Kiuchi M, Zolghadr R, Liaghat G, Tafti RA, Tehrani MS (2014) Flange wrinkling in flexible roll forming process Kasaei MM, Naeini HM, Abbaszadeh B, Mohammadi M, Ghodsi M, Kiuchi M, Zolghadr R, Liaghat G, Tafti RA, Tehrani MS (2014) Flange wrinkling in flexible roll forming process
51.
go back to reference Dietl T, Sedlmaier A (2017) Neue Konzepte für konventionelles und 3D Walzprofilieren. Steuerung Umformverfahren Anwendungen Dietl T, Sedlmaier A (2017) Neue Konzepte für konventionelles und 3D Walzprofilieren. Steuerung Umformverfahren Anwendungen
Metadata
Title
Flexible 3D Profile Roll Forming Technology
Authors
Yong Sun
Albert Sedlmaier
Qiuquan Guo
Dongxing Zhang
Hui Xia
Shiyi Cu
Jie Dong
Yinwang Ren
Copyright Year
2022
Publisher
Springer Nature Singapore
DOI
https://doi.org/10.1007/978-981-19-1348-8_5

Premium Partners