Flexible roll forming processes enable the production of profiles with variable widths, which are used as space-optimized, weight-reduced and load-adapted structural elements. Sheet metal strips are used as the starting workpiece for profile production, which are cut to the desired initial contour after being unwound from the coil.

As part of current research projects, the cutting of these strips is to be replaced by forging and rolling processes, which can reduce waste by up to 30 %. The influence of the induced residual stresses on the roll forming process is to be investigated numerically as part of this thesis.

The following work packages are to be processed for this purpose:

• Familiarization with the state of the art
• Definition of quality criteria for the evaluation of the roll forming result
• Identification of relevant geometric and technological parameters influencing the flexible roll forming process
• Evaluation and interpretation of the simulation results

Research method

Theoretical, numerical