Profile straightening by partial rolling during roll forming

Abstract

The aim of this research project is to develop a new procedure and methodology for straightening profiles by partial rolling of the profile cross-section. Defective profiles are to be eliminated in the production process itself by a partial rolling out of selected cross-section segments. The working hypothesis postulates that profile defects are caused by longitudinal strain distributions and can consequently be avoided by eliminating the strain differences.

Process chain and integration of the diagnostic tool

Motivation

Current sustainability goals include efficient use of resources. As roll-formed products cover a large share of the world's steel production, it is a goal to minimise scrap in this industry. In addition, there is increasing product diversification in this sector, which increases the demands on the flexibility of the production process and on set-up and straightening times. At the same time, there are uncertainties in the semi-finished product and thus fluctuating sheet properties, so that the goal must be to increase the robustness of profile straightening and to reduce straightening iterations. In order to achieve the objectives of reducing emissions and increasing economic efficiency, a reliable and efficient process for straightening profiles is to be developed.

Objective

A new procedure and methodology for straightening profiles by partial rolling of the profile cross-section is to be developed within the scope of this project. A calculation model should make it possible to determine the relative longitudinal strain distribution over the cross-section on the basis of the occurring deviations of the profile from the straightness and to derive targeted measures in the form of a partial rolling of the profile cross-section on the basis of this.

Methodical approach

Within the scope of this project, numerical and experimental investigations are to be carried out in order to identify and quantify the influencing variables on the longitudinal strain and the deviations of the profile straightness. Based on the findings, an analytical model for predicting the longitudinal strain distribution and effective countermeasures by partial rolling shall be derived. This is to be based on geometric approaches and applicable for three-dimensionally curved and twisted profiles.

Acknowledgment

The PtU would like to thank the “Arbeitsgemeinschaft industrieller Forschungsvereinigungen “Otto von Guericke” e.V. (AiF)”, the Research Association for Steel Applications (FOSTA) for their support within the framework of the project. (AiF), and the following project partners. (FOSTA), and the following project partners:

AIRBUS GmbH

GEBHARDT STAHL GmbH

HERKULES GmbH

DataM GmbH

LINDE+WIEMANN SE & Co.KG

WAELZHOLZ GmbH & Co.KG

DREISTERN GmbH & Co.KG

HÖRMANN Automotive Gustavsburg GmbH

KIRCHHOFF&LEHR GmbH

PROFILMETALL GmbH

TILLMANN PROFIL GmbH

UBECO GmbH