Investigation of Web Warping of Profiles with Changing Cross Section in Flexible Roll Forming Process

Flexible roll forming is a modern process for producing profiles with changing cross section. One of the important defects in this process is the web warping of product that causes failure to obtain dimensional and geometrical tolerances. In this paper، mechanism of web warping occurrence was investigated by finite element simulation in ABAQUS/CAE software. Results of simulation indicated that inadequate longitudinal strain in the edge of profile’s flange in transition zone is the reason of profile’s web warping. Furthermore، the effect of geometric parameters of product such as flange length، bend angle، radius of transition zone and thickness on the web warping were determined. Analysis of variance showed flange length and bend angle are recognized as the most effective factors on warping of profiles with specific thickness. An equation for prediction of warping was proposed in terms of geometrical parameters of product. In order to verify the finite element model، the longitudinal strain of deformed strip edge was obtained from simulations and compared with the experimental results of other researchers. A good agreement between them confirmed the accuracy of the finite element model.