Geometry Effects of Asymmetrical Channel Sections on Common Defects in the Roll Forming Process

In this research, the twist and the longitudinal bow defects were studied by finite element analysis in the asymmetrical channel sections. Effects of the geometrical properties including the strip thickness, the web width, and the flange width were investigated on the above effects. Some experiments were performed on an industrial roll-forming machine to verify the accuracy of the finite element model. The results showed that the twist angle decreases with the increase of both strip thickness and web width. However, the twist angle increases with the increase of flanges width. Also the variations of the longitudinal bow height are similar to those of the average residual longitudinal strain of both flange edges.