Investigation of the effective factors on strain distribution in round section roll forming process using the design of experiments

Geometric defects of the roll forming process are affected by amount and situation of the strains distribution. In this work, simulation of the round section roll forming process has been implemented using the finite element method. Effective factors on the strain distribution have been investigated. Roller diameter, distance between the stations and line speed of the sheet as input parameters and maximum longitudinal strain and strain distribution uniformity of across the sheet was considered as the response functions. Design of experiments was conducted using the central composite design (CCD). They were executed by finite elemet method and then values were extracted for response functions. The effect of input parameters to the function response was investigated using the analysis of variance. The results of tests were indicated and discussed by the main and interactions effects diagrams. The results demonstrated that according to the analysis of variance and main effect diagrams, with increasing the distance of stations and roller diameter, the maximum longitudinal strain is reduced. According to the analysis of variance On the other hand, the line speed of sheet and roller diameter affecte on the transverse strain distribution, but variation domain is very low. Also distance between the stations has not efficient effect on the transverse strain distribution.