08-25-2021, 06:07 AM
The presented paper provides a modelling strategy for roll forming of a high strength aluminum alloy tube. Roll forming allows the cost-effective production of large quantities of long profiles. Forming of high strength aluminum brings challenges like high springback and poor formability due to the low Young’s modulus, low ductility and high yield strength. Forming processes with high strength aluminum, such as the AA7075 alloy, therefore require a detailed process design. Three different forming strategies, one double radius strategy and two W-forming strategies are discussed in the paper. The paper addresses the question whether common roll forming strategies are appropriate for the challenge of roll forming of a high strength aluminum micro channel tube. For this purpose, different forming strategies are investigated numerically regarding buckling, longitudinal strain distribution and final geometry. While geometry is quite the same for all strategies, buckling and strain distribution differ with every strategy. The result of the numerical investigation is an open tube that can be welded into a closed tube in a subsequent step. Finally, roll forming experiments are conducted and compared with the numerical results.Current research in production technology focuses primarily on increasing resource efficiency and thus follows the approach of fundamental sustainability of processes and products. High strength aluminum alloys (e.g. AA7075) are commonly used in aerospace applications in spite of their high cost of about 5 €/kg and poor formability [1]. Due to ambitious legal requirements, such as the CO2 target in automotive engineering, new lightweight construction concepts are still needed [2]. An excellent basis is offered by the production of high strength AA7075 thin walled tubes as semi-finished products by roll forming. These can be further processed in subsequent customized processes such as welding, stamping, cutting or rotary swaging.
lead to large elongation of the band edge and thus to buckling. For circular sections (e.g. tube), the BLS is 5–10 times higher than the BLS for a U-profile [6].Groche et al. [11], Park et al. [7], Zou et al. [12] and Lee et al. [13] showed that roll forming of high strength materials and especially of high strength aluminum drawn tube brings challenges compared to commonly roll formed steel grades. High strength leads to high springback and thus to less dimensional accuracy in the processed part. Parameters, which have an influence on springback are shown in Table 1. Difficulties regarding aluminum include early fracture due to low ductility, higher springback and redundant deformation. This requires a well-designed forming strategy in order to get the lowest possible springback and buckling in the roll forming process and the best quality of the processed part. In contrast, aluminum shows a good-natured behavior with regard to buckling due to a higher value of BLS compared to steel [14].The single radius-forming strategy has the advantage to form tubes with different sheet thickness on the same tool. A flower pattern with constant bending radius over the entire cross-section of the sheet is characteristic for the single radius-forming. For high-strength materials, the single radius-forming strategy is not applicable due to high springback caused by the high elastic bending content [10, 18].
uniform increments and to keep the longitudinal strain low in the band edge. The further approach is to calculate the stresses of the formed tube to arrive at the number of passes required. Forming strategy 2R is the first strategy numerically investigated by the FE-software Marc Mentat.In this paper, roll forming of a high strength extruded aluminum tube is investigated. Due to the difficult determination of the design parameters, roll forming of high strength aluminum is a challenge. Conventional roll forming strategies quickly reach their limits when forming aluminum or high strength steels. To form a tube out of high-strength aluminum alloys such as AA7075, a W-forming strategy is recommended. Another positive influence is the application of a down-hill strategy. The investigations have shown that an efficient roll forming production line for high strength aluminum tubes can be set up even with a small number Axial crash of thin-walled circular seamless aluminum tube is investigated in this study. These kinds of tubes usually are used in automobile and train structures to absorb the impact energy. An explicit finite element method (FEM) is used to model and analyse the behaviour. Formulation of the energy absorption and the mean crash force in the range of variables is presented using design of experiments (DOE) and response surface method (RSM). Comparison with experimental tests has been accomplished in some results for validation. Also, comparison with the analytical aspect of this problem has been done. Mean crash force has been considered as a constraint as its value is directly related to the crash severity and occupant injury. The results show that the triggering causes a decrease in the maximum force level during crash.
lead to large elongation of the band edge and thus to buckling. For circular sections (e.g. tube), the BLS is 5–10 times higher than the BLS for a U-profile [6].Groche et al. [11], Park et al. [7], Zou et al. [12] and Lee et al. [13] showed that roll forming of high strength materials and especially of high strength aluminum drawn tube brings challenges compared to commonly roll formed steel grades. High strength leads to high springback and thus to less dimensional accuracy in the processed part. Parameters, which have an influence on springback are shown in Table 1. Difficulties regarding aluminum include early fracture due to low ductility, higher springback and redundant deformation. This requires a well-designed forming strategy in order to get the lowest possible springback and buckling in the roll forming process and the best quality of the processed part. In contrast, aluminum shows a good-natured behavior with regard to buckling due to a higher value of BLS compared to steel [14].The single radius-forming strategy has the advantage to form tubes with different sheet thickness on the same tool. A flower pattern with constant bending radius over the entire cross-section of the sheet is characteristic for the single radius-forming. For high-strength materials, the single radius-forming strategy is not applicable due to high springback caused by the high elastic bending content [10, 18].
uniform increments and to keep the longitudinal strain low in the band edge. The further approach is to calculate the stresses of the formed tube to arrive at the number of passes required. Forming strategy 2R is the first strategy numerically investigated by the FE-software Marc Mentat.In this paper, roll forming of a high strength extruded aluminum tube is investigated. Due to the difficult determination of the design parameters, roll forming of high strength aluminum is a challenge. Conventional roll forming strategies quickly reach their limits when forming aluminum or high strength steels. To form a tube out of high-strength aluminum alloys such as AA7075, a W-forming strategy is recommended. Another positive influence is the application of a down-hill strategy. The investigations have shown that an efficient roll forming production line for high strength aluminum tubes can be set up even with a small number Axial crash of thin-walled circular seamless aluminum tube is investigated in this study. These kinds of tubes usually are used in automobile and train structures to absorb the impact energy. An explicit finite element method (FEM) is used to model and analyse the behaviour. Formulation of the energy absorption and the mean crash force in the range of variables is presented using design of experiments (DOE) and response surface method (RSM). Comparison with experimental tests has been accomplished in some results for validation. Also, comparison with the analytical aspect of this problem has been done. Mean crash force has been considered as a constraint as its value is directly related to the crash severity and occupant injury. The results show that the triggering causes a decrease in the maximum force level during crash.