Dimpling process in cold roll metal forming by finite element modelling and experimental validation
Journal article
Authors | Nguyen, Van Bac, Wang, Chang, Mynors, Diane, English, Martin and Castellucci, Michael |
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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. |
Keywords | Steel strength; Finite Element analysis; Dimpling process; Plastic strength |
Year | 2014 |
Journal | Journal of Manufacturing Processes |
Publisher | Elsevier |
ISSN | 15266125 |
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 dates | Aug 2014 |
Publication process dates | |
Deposited | 21 Feb 2017, 15:15 |
Contributors | Hadley Industries plc, University of Wolverhampton and University of Sussex |
File | File Access Level Open |
https://repository.derby.ac.uk/item/9416v/dimpling-process-in-cold-roll-metal-forming-by-finite-element-modelling-and-experimental-validation
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