Numerical and experimental study of the edge wrinkling defect of cold roll forming of wide profiles

The Cold roll forming is a complex forming process which quality of its products is highly dependent on the process parameters. The edge wrinkling defect is one of the common defects in the cold roll forming process of wide profiles. Edge wrinkling leads to several problems such as decrease in dimensional quality¡ wearing of forming rolls due to contact with the buckled edge and non-uniform distribution of forming forces through the production line. In order to investigate the edge wrinkling defect in this study¡ the finite element simulation and experimental tests were used. At first¡ for validation of simulation results¡ one model in exact in accordance with experimental set up and with one holding station and one forming station to produce one trapezoidal profile was created. Then by simulating this process in Abaqus software and comparing the longitudinal strain in simulation and experimental results¡ the numerical model was validated. After verifying the numerical model¡ it was used for simulating a similar profile with two channels in transversal direction and in three forming stations and then the effect of sheet material (yield stress and work hardening exponent)¡ strip thickness and distance between the roll stands are investigated on the edge wrinkling defect of products. Results of this study show that wrinkling increases with the yield stress increase¡ but decreases with increase in work hardening exponent¡ strip thickness and distance between the roll stands.