Minimizing the edge buckling of the cold roll-forming process

Abstract

In this work, the cold roll-forming process was numerically simulated by MSC SuperForm 2002 software based on finite element method. The strips were modelled with U-profile and a pre-punched hole located at the web zone was introduced. Two different configurations of the roll-forming mills were simulated, named as the Conventional and Curved. The conventional roll-forming mill was obtained by using the same diameters of the bottom rolls. The downhill roll-forming mill was achieved by increasing the diameters of the bottom rolls. This study investigated the occurrence of edge buckling in the hole lateral edge of the pre-punched sheet during the forming process. It could be concluded that, during the cold roll-forming process, reducing or even eliminating the compression stress in the web zone by the downhill roll-forming mill is possible to minimize occurrence of the edge buckling in the hole lateral edge of the pre-punched sheet during the forming process.