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Optimization of the Spring-Back in Roll Forming Process with Finite Element Simulation

Ya. Zhang, Ha-Phong. Nguyen, and Dong-Won. Jung
Department of Mechanical Engineering, Jeju National University, Jeju, Republic of Korea

Abstract—This study presents a finite model of U-bending roll forming process with COPRA software. Based on the design and simulation of the U-bending’s roll forming process, the bending and spring-back regulations are investigated. A number of U-bending processes are also analyzed in order to determine the springback level. The material used in this roll forming process is Mg-Al alloy. There are many factors which have a significant influence in the forming process, such as the width of the U-bending, the radius of the roll die, lubrication, roll velocity and sheet thickness. In order to predict the performance of the sheet forming process and improve the spring-back, the FEM method and Taguchi method are used in this sheet process design. The sheet with 1, 2 and 3mm thickness pass through 6 stages of bending process. Every stage is uniform with 15°. With three kinds of widths of the U-bending and 3 kinds of radius, there are total 9 simulations are established in this study. The optimal design parameters are obtained with the minimum spring-back angle and the sheet forming quality has been controlled. 
Index Terms—U bending, spring back, taguchi method, FE simulation

Cite: Ya. Zhang, Ha-Phong. Nguyen, and Dong-Won. Jung, "Optimization of the Spring-Back in Roll Forming Process with Finite Element Simulation," International Journal of Mechanical Engineering and Robotics Research, Vol. 5, No. 4, pp. 272-275, October 2016. DOI: 10.18178/ijmerr.5.4.272-275