Finite element study on chain-die

forming of an AHSS channel with

variable depth
Presenter: Franck Morel BENE FANKEM
Supervisor: Prof. Li Dayong
Paper id : S1009 ▪ 2019/11/8
Contents

1 Introduction and related work

2 Chain-die forming

3 Research method on variable depth product

4 Results

5 Questions and answers

Contents

1 Introduction and related work

2 Chain-die forming

3 Research method on variable depth product

4 Results and future works

5 Questions and answers

 单击此处编辑母版标题样式 Page
4 .

Introduction

Did you know? About 50% of car frames are made of higher
strength steels

LEGEND
AHSS
High Strength Steel
Steel
The 2019 Chevrolet Silverado 1500
Aluminium
Courtesy of GM
Introduction
Typical variable shape products

Some common cold forming technologies* :

for variable width
 stamping
 Roll forming

for variable depth:

 flexible roll forming
 单击此处编辑母版标题样式 Page
6 .

Variable depth related work and problem

statement

[1]

• The tooling needs to follow vertically the path given by the web and
• the tool axes need to be perpendicular to the tool path throughout the
whole motion

* Bending is only performed in the longitudinal direction.

单击此处编辑母版标题样式 Page
7 .

Variable depth related work and problem

statement

[2]
Lingren used a machine developed by ORTIC AB having six
forming stands where every stand has four units. The units have
a servo control axis, two translations and two rotations axis.

**Up to six passes are required and bending is also only in the
longitudinal direction.
1 Introduction and related work

2 Chain-die forming

3 Research method on variable depth product

4 Results and future works

5 Questions and answers

单击此处编辑母版标题样式 Page
9 .

Chain-die forming

[3]
单击此处编辑母版标题样式 Page
10 .

Chain-die forming

[4] Comparism of deformation length between roll forming and Chain die forming
单击此处编辑母版标题样式 Page
11 .

Chain-die forming

[5]
1 Introduction and related work

2 Chain-die forming

3 Research method on variable depth product

4 Results and future works

5 Questions and answers

单击此处编辑母版标题样式 Page
13 .

Research method on variable depth product

 Desired product

*dimensions in mm
 单击此处编辑母版标题样式 Page
14 .

Research method on variable depth product

 Local feature definition

*a quarter section is considered

 单击此处编辑母版标题样式 Page
15 .

Research method on variable depth product

 Meshing strategy

Feed
direction
单击此处编辑母版标题样式 Page
16 .

Research method on variable depth product

 Plastic strain analysis method

1 Introduction and related work

2 Chain-die forming

3 Research method on variable depth product

4 Results and future works

5 Questions and answers

 单击此处编辑母版标题样式 Page
18 .

Results

 Effective plastic strain analysis

 The highest strain concentrations are on the inner surface and outer
surface of the blank corner.
 Overall, the middle zone exhibits the maximum strain of 0.1925 on
its inner region and 0.1765 on the outer region.
 There is a negligeable amount of plastic strain in the web and
sidewall of the middle zone, and almost no redundant plastic strain in
that of the head and tail zones except for the deformation region (the
corner).
 单击此处编辑母版标题样式 Page
19 .

Results

 Forming limit check at one critical region

 One critical consideration for variable depth profiles which makes

forming difficult for other forming methods is that the concave zone
of the corner experiences both transverse and longitudinal loading
simultaneously.
 Both bend corners radii can be formed without cracking.
 单击此处编辑母版标题样式 Page
20 .

 Thickness distribution along longitudinal paths

 单击此处编辑母版标题样式 Page
21 .

Springback development

 Springback comparism of entire convex zone

• A springback of about 2mm is observed in the convex web of the

1.2mm corner radius part as opposed to about 2.5mm on the 5mm
corner radius part.
• This reveals a direct relationship between the corner radius and the
web bow.
 单击此处编辑母版标题样式 Page
22 .

Springback development

 Springback comparism of concave zone

• An inverse relationship is observed in the concave corner between the

corner radius and the web bow.
• There is a larger springback of only about 1mm which occurs in the
R5 corner in contrast to about 0.5mm in the R1.2 corner.
 单击此处编辑母版标题样式 Page
23 .

References

[1] Abeyrathna B, Rolfe B, Pan L, Ge R and Weiss M 2016 Flexible roll

forming of an automotive component with variable depth Advances in
Materials and Processing Technologies 2 527-538
[2] Lindgren M 2007 Cold roll forming of a U-channel made of high
strength steel Journal of Materials Processing Technology 186 77- 81
[3] Li Y, Sun Y, Xiao H, Bong H J, Shi L, Li S, Li D Y, Ding S C and
Wagonere R H 2018 A numerical study on chain-die forming of the AHSS U-
channel and contrast with roll forming International Journal of Mechanical
Sciences 135 279-293
[4] Sun Y, Li Y, Daniel J.T.W, Paul A, Liuc Z, Ding S.C. 2017 Analytical and
numerical analyses of the longitudinal plastic strain and web- warping in
Chain-die-formed AHSS sections with variable widths Journal of Materials
Processing Technology 243 322–334
[5] Li Y, Research on Chain-die Forming of Advanced High Strength Steel U-
Channels, Phd Thesis, Shanghai Jiaotong University.
 THANKS ！

ANY QUESTIONS ?