Numerical And Experimental Investigation Of Twisting Defect Of Symmetrical Channel Section With Asymmetrical Holes Formed By Cold Roll Forming

The roll forming of an asymmetrical channel section is associated with a twisting defect, but this defect also occurs in a symmetrical section whose holes are asymmetrical. Therefore, first, a finite element model was presented to investigate the process. By designing the full factorial method, the important factors affecting the twisting defect and the effect of each during the cold roll forming process have been investigated. In the end, it was concluded that the thickness of the sheet and the diameter of the holes are the most important factors affecting the twisting defect. It was concluded that the greater the difference in the diameter of the holes on both sides of the channel, the higher the amount of twisting defect. For the forming angle of 45 degrees, by increasing the thickness of the sheet from 2 mm to 3 mm, the twist angle of the piece increased from 1.5 degrees to 2.5 degrees. According to the behavior of the metal, a series of experimental tests were designed and the effect of the hole diameter factor on this defect was determined. Appropriate matching of experimental and numerical results indicates reliable and verifiable numerical results.