Dimpling process in cold roll metal forming by finite element modelling and experimental validation

Journal article


Nguyen, Van Bac, Wang, Chang, Mynors, Diane, English, Martin and Castellucci, Michael 2014. Dimpling process in cold roll metal forming by finite element modelling and experimental validation. Journal of Manufacturing Processes. https://doi.org/10.1016/j.jmapro.2014.03.001
AuthorsNguyen, Van Bac, Wang, Chang, Mynors, Diane, English, Martin and Castellucci, Michael
Abstract

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 material properties that occur in the process, it is necessary to accurately simulate the process and validate through physical tests. In this paper, 3D non-linear finite element analysis was employed to simulate the dimpling process and mechanical testing of the subsequent dimpled sheets, in which the dimple geometry and material properties data were directly transferred from the dimpling process. Physical measurements, tensile and bending tests on dimpled sheet steel were conducted to evaluate the simulation results. Simulation of the dimpling process identified the amount of non-uniform plastic strain introduced and the manner in which this was distributed through the sheet. The plastic strain resulted in strain hardening which could correlate to the increase in the strength of the dimpled steel when compared to plain steel originating from the same coil material. A parametric study revealed that the amount of plastic strain depends upon on the process parameters such as friction and overlapping gap between the two forming rolls. The results derived from simulations of the tensile and bending tests were in good agreement with the experimental ones. The validation indicates that the finite element analysis was able to successfully simulate the dimpling process and mechanical properties of the subsequent dimpled steel products.

KeywordsSteel strength; Finite Element analysis; Dimpling process; Plastic strength
Year2014
JournalJournal of Manufacturing Processes
PublisherElsevier
ISSN15266125
Digital Object Identifier (DOI)https://doi.org/10.1016/j.jmapro.2014.03.001
Web address (URL)http://hdl.handle.net/10545/621446
http://creativecommons.org/licenses/by-nc-nd/4.0/
hdl:10545/621446
Publication datesAug 2014
Publication process dates
Deposited21 Feb 2017, 15:15
ContributorsHadley Industries plc, University of Wolverhampton and University of Sussex
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