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

Hdl Handle:
http://hdl.handle.net/10545/621446
Title:
Dimpling process in cold roll metal forming by finite element modelling and experimental validation
Authors:
Nguyen, Van Bac; Wang, Chang; Mynors, Diane; English, Martin; 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.
Affiliation:
Hadley Industries plc; University of Wolverhampton; University of Sussex
Citation:
Nguyen, Van Bac et al (2014) 'Dimpling process in cold roll metal forming by finite element modelling and experimental validation', Journal of Manufacturing Processes, 16(3), pp. 363–372
Publisher:
Elsevier
Journal:
Journal of Manufacturing Processes
Issue Date:
Aug-2014
URI:
http://hdl.handle.net/10545/621446
DOI:
10.1016/j.jmapro.2014.03.001
Additional Links:
http://www.sciencedirect.com/science/article/pii/S1526612514000358
Type:
Article
Language:
en
ISSN:
15266125
Sponsors:
N/A
Appears in Collections:
Department of Mechanical Engineering & the Built Environment

Full metadata record

DC FieldValue Language
dc.contributor.authorNguyen, Van Bacen
dc.contributor.authorWang, Changen
dc.contributor.authorMynors, Dianeen
dc.contributor.authorEnglish, Martinen
dc.contributor.authorCastellucci, Michaelen
dc.date.accessioned2017-02-21T15:15:05Z-
dc.date.available2017-02-21T15:15:05Z-
dc.date.issued2014-08-
dc.identifier.citationNguyen, Van Bac et al (2014) 'Dimpling process in cold roll metal forming by finite element modelling and experimental validation', Journal of Manufacturing Processes, 16(3), pp. 363–372en
dc.identifier.issn15266125-
dc.identifier.doi10.1016/j.jmapro.2014.03.001-
dc.identifier.urihttp://hdl.handle.net/10545/621446-
dc.description.abstractThe 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.en
dc.description.sponsorshipN/Aen
dc.language.isoenen
dc.publisherElsevieren
dc.relation.urlhttp://www.sciencedirect.com/science/article/pii/S1526612514000358en
dc.rights.urihttp://creativecommons.org/licenses/by-nc-nd/4.0/en
dc.subjectSteel strengthen
dc.subjectFinite Element analysisen
dc.subjectDimpling processen
dc.subjectPlastic strengthen
dc.titleDimpling process in cold roll metal forming by finite element modelling and experimental validationen
dc.typeArticleen
dc.contributor.departmentHadley Industries plcen
dc.contributor.departmentUniversity of Wolverhamptonen
dc.contributor.departmentUniversity of Sussexen
dc.identifier.journalJournal of Manufacturing Processesen
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