A new mathematical model for determining the longitudinal strain in cold roll forming process

Cold roll forming (CRF) is an important sheet metal forming process that is widely studied through experiments and numerical simulations. Mathematical analysis is a more efficient and economical tool to examine CRF, but little attention has been given to it for a long time. In this study, a new mathematical model is developed to analyze the bend angle distribution and longitudinal strain development in the deformation process. Calculation results using this new model agree well with the experimental data in the available literature. The effects of flange length and roll dimension on the peak longitudinal strain are also investigated. The findings are expected to help process designers predict longitudinal strain development before the roll design is implemented in practical production.

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