Appropriate Flower Pattern for Cold Roll Forming of Hat Channel Section

Cold roll forming process is a process that a strip passes through a collection of rotary rolls to be converted to a desired profile. Hat channel section is one of the roll forming products that has many applications in various industries especially in automotive industry. In the present study proper flower pattern for production of hat channel section is determined. Proper flower pattern in the cold roll forming process can prevent some defects such as bowing and wrinkling. Flower pattern of hat channel section was predicted by ABAQUS 3D simulation. Longitudinal strain is one of the results of simulation which was used as a criterion for product quality evaluation. Results of simulations were verified by experimental tests for first forming stand of hat channel section which were done in the present study. In the experimental part of present study, effect of roll angle was investigated on the bow defect of product. Experimental and numerical results of this study have a good agreement. Numerical and experimental of this study showed that bow defect increases by increasing bending angle.