Skip to main content
SpringerLink
Log in

Springback and longitudinal bow in chain-die forming U and hat channels

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Springback and longitudinal bow are two major shape defects in gradual forming processes like chain-die forming and roll forming. In this study, the springback and longitudinal bow of AHSS in chain-die forming of hat and U profiles are investigated through experiment and finite element simulation. The disparity of springback along the longitudinal direction and longitudinal bow signifies complex deformation during chain-die forming. Based on finite element simulation of the chain-die forming, the gradual forming process realized by sequential die blocks causes bending and reverse-bending in the web area and redundant deformation of the sheet metal, which leads to nonuniform bending moment and accumulated stresses along the longitudinal direction. At the same time, the redundant deformation will also result in the longitudinal strain on the edge, while the downhill characteristic of chain-die forming reduces the maximum longitudinal strain on the edge and introduces longitudinal strain on the web. The nonuniform longitudinal strain distribution along the transversal direction causes disparate downward and upward bowing longitudinal bow for chain-die formed AHSS hat and U profiles. By the established model, the disparate springback and longitudinal bow behavior can be quantitatively evaluated, which is helpful to chain-die forming process design.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9.
Fig. 10.
Fig. 11.
Fig. 12.
Fig. 13.
Fig. 14.
Fig. 15.
Fig. 16.
Fig. 17.
Fig. 18.
Fig. 19.
Fig. 20.
Fig. 21.
Fig. 22.
Fig. 23.
Fig. 24.
Fig. 25.
Fig. 26.
Fig. 27.
Fig. 28.
Fig. 29.

Similar content being viewed by others

Data availability

The data and materials supporting the results of this article are included within the article.

References

  1. Askari-Paykani M, Shahverdi HR, Miresmaeili R (2016) First and third generations of advanced high-strength steels in a FeCrNiBSi system. J Mater Process Technol 238:383–394. https://doi.org/10.1016/j.jmatprotec.2016.07.043

    Article  Google Scholar 

  2. Zhou M, Li Y, Hu Q, Li X, Chen J (2019) Investigations on edge quality and its effect on tensile property and fracture patterns of QP980. J Manuf Process 37:509–518. https://doi.org/10.1016/j.jmapro.2018.12.028

    Article  Google Scholar 

  3. Hazra S, Efthymiadis P, Proprentner D, Shollock B, Dashwood R (2017) The strain fields present during the bending of ultra-high strength steels. Procedia Eng 207:1314–1319. https://doi.org/10.1016/j.proeng.2017.10.889

    Article  Google Scholar 

  4. Traub T, Chen X, Groche P (2017) Experimental and numerical investigation of the bending zone in roll forming. Int J Mech Sci 131–132:956–970. https://doi.org/10.1016/j.ijmecsci.2017.07.056

    Article  Google Scholar 

  5. Park JC, Yang DY, Cha MH, Kim DG, Nam JB (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 86:68–80. https://doi.org/10.1016/j.ijmachtools.2014.07.001

    Article  Google Scholar 

  6. Deole AD, Barnett MR, Weiss M (2018) The numerical prediction of ductile fracture of martensitic steel in roll forming. Int J Solids Struct 144–145:20–31. https://doi.org/10.1016/j.ijsolstr.2018.04.011

    Article  Google Scholar 

  7. Zhang Y, Ding S (2012) A comparison study of Chain-die Forming and roll forming by forming a top hat section. 14th Int Conf Met Forming Ger Akad Górniczo-Hutnicza Kraków 703–6

  8. Li Y, Liang Z, Zhang Z, Zou T, Li D, Ding S, Xiao H, Shi L (2019) An analytical model for rapid prediction and compensation of springback for chain-die forming of an AHSS U-channel. Int J Mech Sci 159:195–212. https://doi.org/10.1016/j.ijmecsci.2019.05.046

    Article  Google Scholar 

  9. Qian Z, Sun Y, Meehan PA, Daniel WJT, Ding S (2017) Experimental and numerical investigation of flange angle in Chain-die formed AHSS U-channel sections. Int J Adv Manuf Technol 92:1231–1242. https://doi.org/10.1007/s00170-017-0159-7

    Article  Google Scholar 

  10. Wiebenga JH, Weiss M, Rolfe B, van den Boogaard AH (2013) Product defect compensation by robust optimization of a cold roll forming process. J Mater Process Technol 213:978–986. https://doi.org/10.1016/j.jmatprotec.2013.01.006

    Article  Google Scholar 

  11. 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 252:782–794. https://doi.org/10.1016/j.jmatprotec.2017.10.048

    Article  Google Scholar 

  12. Wagoner RH, Lim H, Lee MG (2013) Advanced Issues in springback. Int J Plast 45:3–20. https://doi.org/10.1016/j.ijplas.2012.08.006

    Article  Google Scholar 

  13. Badr OM, Rolfe B, Zhang P, Weiss M (2017) Applying a new constitutive model to analyse the springback behaviour of titanium in bending and roll forming. Int J Mech Sci 128–129:389–400. https://doi.org/10.1016/j.jmatprotec.2007.08.073

    Article  Google Scholar 

  14. Halmos GT (2005) Roll forming handbook. CRC Press, New York

    Book  Google Scholar 

  15. Bui QV, Ponthot JP (2008) Numerical simulation of cold roll-forming processes. J Mater Process Technol 202:275–282. https://doi.org/10.1016/j.jmatprotec.2007.08.073

    Article  Google Scholar 

  16. Abvabi A, Rolfe B, Hodgson PD, Weiss M (2015) The influence of residual stress on a roll forming process. Int J Mech Sci 101–102:124–136. https://doi.org/10.1016/j.ijmecsci.2015.08.004

    Article  Google Scholar 

  17. Gi CW, Kim N (2013) Study on twisting and bowing of roll formed products made of high strength steel. Int J Precis Eng Manuf 14:1527–1533. https://doi.org/10.1007/s12541-013-0206-8

    Article  Google Scholar 

  18. Jeong SH, Lee SH, Kim GH, Seo HJ, Kim TH (2008) Computer simulation of U-channel for under-rail roll forming using rigid-plastic finite element methods. J Mater Process Technol 201:118–122. https://doi.org/10.1016/j.jmatprotec.2007.11.130

    Article  Google Scholar 

  19. Shirani Bidabadi B, Moslemi Naeini H, Salmani Tehrani M, Barghikar H (2016) Experimental and numerical study of bowing defects in cold roll-formed, U-channel sections. J Constr Steel Res 118:243–253. https://doi.org/10.1016/j.jcsr.2015.11.007

    Article  Google Scholar 

  20. Badr OM, Rolfe B, Weiss M (2018) Effect of the forming method on part shape quality in cold roll forming high strength Ti-6Al-4V sheet. J Manuf Process 32:513–521. https://doi.org/10.1016/j.jmapro.2018.03.022

    Article  Google Scholar 

  21. Sun Y, Li Y, Daniel WJT, Meehan PA, Liu Z, Ding S (2017) Longitudinal strain development in Chain-die forming AHSS products: Analytical modelling, finite element analysis and experimental verification. J Mater Process Technol 243:322–334. https://doi.org/10.1016/j.jmatprotec.2016.12.019

    Article  Google Scholar 

  22. Li Y, Sun Y, Xiao H, Bong HJ, Shi L, Li S, Li D, Ding S, Wagoner RH (2018) A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming. Int J Mech Sci 135:279–293. https://doi.org/10.1016/j.ijmecsci.2017.11.034

    Article  Google Scholar 

  23. Qian Z, Sun Y, Li Y, Wang C, Meehan PA, Daniel WJT, Ding S (2020) Investigation of the design process for the Chain-die forming technology based on the developed multi-stand numerical model. J Mater Process Technol 277:116484. https://doi.org/10.1016/j.jmatprotec.2019.116484

    Article  Google Scholar 

  24. Liu X, Cao J, Chai X, Liu J, Zhao R, Kong N (2017) Investigation of forming parameters on springback for ultra high strength steel considering Young’s modulus variation in cold roll forming. J Manuf Process 29:289–297. https://doi.org/10.1016/j.jmapro.2017.08.001

    Article  Google Scholar 

  25. Phanitwong W, Thipprakmas S (2017) FE-analysis of channel width effects on spring-back characteristics in the U-bending process. Procedia Eng 183:17–22. https://doi.org/10.1016/j.proeng.2017.04.005

    Article  Google Scholar 

  26. Saffe SN, Binti M, Nagamachi T, Ona H (2015) Mechanism of end deformation after cutting of light gauge channel steel formed by Roll Forming. Mater Trans. https://doi.org/10.2320/matertrans.P-M2014842

  27. Radonjic R, Liewald M (2019) New process design for reduction of springback by forming with alternating blank draw-in. Procedia Manuf 29:217–224. https://doi.org/10.1016/j.promfg.2019.02.129

    Article  Google Scholar 

  28. Paralikas J, Salonitis K, Chryssolouris G (2011) Investigation of the effect of roll forming pass design on main redundant deformations on profiles from AHSS. Int J Adv Manuf Technol 56:475–491. https://doi.org/10.1007/s00170-011-3208-7

    Article  Google Scholar 

  29. Ding S, Meehan PA, Daniel WJT (2011) A novel sheet metal forming method—Millipede forming. J Mater Process Technol 211:376–381. https://doi.org/10.1016/j.jmatprotec.2010.10.012

    Article  Google Scholar 

Download references

Acknowledgements

The authors from Shanghai Jiao Tong University acknowledge the financial support of the National Natural Science Foundation of China (Grant No. U1860110). The authors would also like to give many thanks to BaoSteel Research Institute and Ningbo SaiRolf Metal Forming Co., Ltd. for providing experimental materials and facilities.

Funding

This work was supported by the National Natural Science Foundation of China (Grant No. U1860110).

Author information

Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, China

    Zhenye Liang, Yang Liu, Tianxia Zou, Dayong Li & Yinghong Peng

  2. School of Mechanical and Mining Engineering, University of Queensland, St Lucia, Brisbane, QLD, 4072, Australia

    Shichao Ding

  3. Research Institute, Baoshan Iron & Steel Co., Ltd., Shanghai, 201900, China

    Hua Xiao & Lei Shi

  4. State Key Laboratory of Development and Application Technology of Automotive Steels (BaoSteel), Shanghai, 201900, China

    Hua Xiao & Lei Shi

Authors
  1. Zhenye Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yang Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tianxia Zou
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Dayong Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shichao Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Hua Xiao
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Lei Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Yinghong Peng
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Zhenye Liang: Conceptualization, Methodology, Simulation, Experiments, Writing - Original Draft;

Yang Liu: Experiments, Validation;

Tianxia Zou: Resources, Funding acquisition, Supervision;

Dayong Li: Resources, Writing - Review & Editing, Supervision;

Shichao Ding: Conceptualization, Methodology;

Hua Xiao: Resources, Software, Experiments;

Lei Shi: Resources, Software, Experiments;

Yinghong Peng: Resources, Project administration.

Corresponding author

Correspondence to Tianxia Zou.

Ethics declarations

Ethical approval

This work does not contain any ethical issues or personal information.

Consent to participate

No human or animal is involved in this work.

Consent to publish

All authors have given their permission for publishing this work.

Competing interests

The authors declare that they have no known competing interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liang, Z., Liu, Y., Zou, T. et al. Springback and longitudinal bow in chain-die forming U and hat channels. Int J Adv Manuf Technol 116, 3571–3592 (2021). https://doi.org/10.1007/s00170-021-07374-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07374-y

Keyword

Search

Navigation