Numerical and experimental investigation of deformation length in flexible roll forming process

Flexible roll forming process is a novel method for producing profiles with variable cross-section. In this process, to produce the profiles with variable cross-section, the position of the rolls is controlled at any time and moved in accordance with their geometry. In this paper, using finite element simulations and experimental tests, the deformation length is investigated as one of the important parameters in the flexible roll forming process. For this purpose, a finite element model was created in Abaqus software, and then the accuracy of the model was confirmed by comparing the simulation results and experimental data for longitudinal strain in the compression and stretching zones of a channel profile with variable cross-section. The results showed that the deformation length in the flexible roll forming is changed not only in the different zones of the profile, but also in different areas of each zone. The highest deformation length was obtained at the middle of the stretching zone, which is 38% longer than it at the middle of the narrow and wide zones and 48% longer than it at the middle of the compression zone. It was also found that with increasing the forming angle and flange length of the profile, the deformation length increases in all zones of the profile with variable cross-section.