Numerical and Experimental Investigation of Roll Forces and Torques in Cold Roll Forming of a Channel Section

One of the most important issues in the review of cold roll forming process of metals is estimation of force and torque. The optimum production line can be designed determining the effective parameters on force and torque. Some of these parameters are material, sheet thickness, bending angle, lubrication conditions, rolls rotational speed and distance of the stands. The aim of this study is to investigate the effect of thickness, yield strength, sheet width and forming angle plate on the force and torque applied on rolls. So the forming process was 3D simulated in finite element software Marc/mentat. Simulation results showed that with increase of yield strength, thickness and forming angle, applied force and torque on rolls will increase. Also the increase in sheet width- assuming constant flange length- will increase the force on the rolls and reduce the torque needed for forming. The effect of thickness and sheet width was experimentally investigated which verified the results obtained by FEA.