Volume-5 Issue-10

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Abstract: Roll forming is a continuous profile production process to form sheet metal progressively into desired shape with closer tolerances. The process offers several advantages such as complex geometrical shapes, high strength, dimensional accuracy, closer tolerances, and good surface finish. Several parts in automobile body are produced with this process. Conventional roll forming is limited to components with uniform cross-sections; the recently developed flexible roll forming (FRF) process can be used to form components which vary in both width and depth. It has been suggested that this process can be used to manufacture automotive components from UHSS which has limited tensile elongation. In this method, the pre-cut blank is fed through a set of rolls; some rolls are computer-numerically controlled to follow the three dimensional contours of the part and hence parts with variable cross-section can be produced.Several Parts in automobile body are produced with this process. Flexible roll forming process can easily be implemented to current production lines and synchronized with other stamping units. The pipe-shaped thin-walled cross-sections and complex shaped profiles which are difficult to produce by other methods can be produced by roll forming. Nowadays flexible roll forming technology draws more attentions than before in automotive industry.

Keywords: Roll Forming, Sheet Metal, Automotive Industry, Finite Element 

References:

1. Ilyas Kacar, Fahrettin Ozturk. Roll forming applications for automotive industry. OTEKON 2014, 26-27 may 2014, BURSA.(Automotive Technology Congress.)
2. Dongum Kim, MyungHwan Cha, Yeon Sik Kang. The Development of the bus frmae by flexible roll forming. Elsevier, 17^th IC 183[2017] 11-16.
3. B Abeyrathna, A Abvabi, B Rolfe, R Taube, and M Weiss. Numerical analysis of the flexible roll forming of an automotive component from high strength steel.IDDRG2016 Doi10.1088/1757-899x/159/1/012005. IOP Publishing.
4. D.Joo, S.W. Han, S.G.R. Shin and Y.H. Moon. Flexible roll forming process design for variable Cross-Section Profile, DOI 10.1007/s12239-015-0009-2,pISSN 1229-9138.
5. Michael Lindgren. 3d roll-forming of hat-profile with variable depth and width.1^st IC on Roll Forming 14^th -15^th 2009, Bilbao, Spain.SE-781 88
6. Lander Galdos, Unai Ulibarri, Imanol Gil, Rafael Ortubay. Friction cofficient identification in roll forming processes. Vols. 611-612 (2014) pp 425-435. Trans Tech Pub. Switzerland.
7. Reza Rezaei, Hassan Moslemi Naeini, Roohollah Azizi Tafti, Mohammad Mehdi Kasaei, Mehran Mohammadi, Behnam Abbaszadeh. Effect of bend curve on web warping in flexible roll formed profiles.Springer-verlag London 2017 ,3625-3636.
8. Pedro barbieri Figueiredo Ferreira. Roll forming- a study on mahine deflecion by means of experimental analysis and numeical developments
9. Albert Sedlmaier. 3D Flexible roll forming of profile with discontinous cross sections. data M Sheet Metal Solutions.
10. By Andre Abee, Albert Sedlmaier, Carl Stepenson. Development of New 3D roll forming applications by means of numerical analysis as a part of a quality control methodology.Data M Sheet Metal Solution Gmbh, Cold Rolled, CBM
11. Sun Yogn, Qian Zhen, Shi Lei, Daniel J.T. William. Numerical Investigation of the Permanent Longitudinal Strain and Web-warping in Chai-die formed AHSS varible width section.
12. Mohammad Mehdi Kasaei, Reza Rezaei, Hassan Moslemi Naeini, Roohollah Azizi Tafti, Mehdi Salmani Tehrani, Mehran Mohammadi, Behnam Abbaszadeh. Flange wrinkling in flexible roll forming process.Elsevier 11^th IC 81(2014)245-250.
13. Ji-woo Park, Min-gyu Kil, Jeong Kim, Beom-soo Kang. A Predictive Model of Flexibly-reconfigurable Roll Forming Process using Regression Analysis.ICTP 2017 Cambridge, UK, Elsevier.
14. Zhaoxuan Hou, Min Wan, Xiangdong Wu, Xiaomeng Xu. Roll forming of aluminum alloy profile with hat-shaped section. ICAS 2016 & HMns 2016
15. Wang Guiyong, Li Qiang, and Qian Bo. Control System Development for Flexible Roll Forming Machine.AISC 137,pp. 697-705 , Sringer-VBH-2012.
16. S. Chaudhari, S.S. Pimpale. A Flexible Roll Forming: A New Method of Manufacturing variable cross-secion profiles. Volume 1 issue 3, sepetember 2017, ISSN: 2456-8465

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Authors:

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Abstract: Among all the non-ferrous materials, aluminium is widely employed in various aerospace, defence and industrial applications. The natural qualities, of aluminium and its alloys, like lightness, electrical and thermal conductivity, corrosion resistance, suitability for surface treatments, the diversity of the alloys and intermediates, ease of use, recycling make them usable in many applications. The applications demand the manufacturing of components by a superior manufacturing process, so that the products will be without any defects. Welding is one such process which is widely used in fabrication of aluminium components. Both fusion and solid- state welding processes are employed in the manufacturing of aluminium components. An attempt is made in this paper to take an overview of some fusion welding and some solid-state welding processes to weld Al and its alloys with a focus on the process parameters of these processes, tools used, micro structure of the welded specimens, thermal profiles, strength of joints and heat treatment. This is an attempt understand and summarize the issues related to welding of aluminium and its alloys.

Keywords: Process Parameters, Microstructure, Aluminium.

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