Abstract The presented paper provides a modelling strategy for roll forming of high strength AA7075 aluminum tube. Roll allows the cost-effective production large quantities long profiles. Forming brings challenges like springback and poor formability due to low Young’s modulus, ductility yield strength. processes with aluminum, such as alloy, therefore require detailed process design. Three di...

Four-roll bending process is usually used for manufacturing of seamed thick-walled and thin-walled cylinders. Due to complexity of this process, the analytical solution of plate bending in this process has not been developed completely. The existence of friction and multi-step processing makes it more difficult. Investigation of four-roll bending process using analytical and numerical methods i...

Roll-bending technology has a high degree of flexibility and does not require special molds. However, based on the existing plastic mechanics theory finite element simulation, it is difficult to accurately analyze complex spatial relationship profile roll forming. Therefore, fixed-curvature prediction model constructed XGBoost (extreme gradient boosting), coupling effect process parameters mate...

The dimpling process is a novel cold-roll forming process that involves dimpling of a rolled flat strip prior to the roll forming operation. This is a process undertaken to enhance the material properties and subsequent products' structural performance while maintaining a minimum strip thickness. In order to understand the complex and interrelated nonlinear changes in contact, geometry and mate...

The objectives in the cold rolling process include improved sheet surface quality, enhanced steel mechanical strength, and better solidification operations. Given the increasing demand for higher steel...

Hemming is a three-step sheet-folding process utilized in the production of automotive closures. It has a critical impact on the performance and perceived quality of assembled vehicles. Using a two-dimensional finite element model, this paper presents a design-of-experiments (DOE) study of the relationships between important hemming process parameters and hem quality for aluminium alloy AA 6111...

Flexible Roll Forming (FRF) allows the forming of components with a variable cross section along length component. However, process has only limited application in automotive industry due to wrinkling flange which currently prevents high strength steels and limits part shape complexity. This paper presents new technology, Incremental Shape Rolling (ISR), where pre-cut blank is clamped between t...