The effect of process parameters on thinning defect in the cold roll forming process of channel section

Cold roll forming is a sheet metal forming process that it looks simple, but the lot of parameters that influence this process and interaction of this parameters over each other's are challenges. One of the defects that affect the quality of the products in this process, is the thinning. This defect occurs mainly in bending zone is affected by the parameters of the process. Parameters such as forming angle, sheet thickness, roller diameter, roller corner radius and distance between stations have a major effect on the occurrence of fructure. In this paper, the roller corner radius, forming angle and sheet thickness have been investigated to the thinning defect in this process. Cold roll forming experiments for this study has been done and the Abaqus finite element simulation software used to predict the thinning in the bending zone. St52 steel sheet was used to experiments. The results showed that from three parameters investigated in this paper the radius of the corner of 5mm with 41.7% and forming angle of 600 whit 40.7% have the greatest effects on this defect. In fact for reduction of transverse strains in bending zone it is better that forming angle decrease so the number of forming stations increase.