Validation of a finite element model of the cold roll forming process on the basis of 3D geometric accuracy

Abstract Cold roll forming is an incremental sheet metal forming process used to supply products to numerous industries such as automotive, architecture and construction, etc. In recent years there has been an increase in the demand by customers for high value products, through the forming of high strength materials, or complex profiles. Such demands increase the challenges faced by the tooling designer to bring a successful product through from design to manufacture, on time and within specification. Finite element (FE) simulations are increasingly applied in industry due to the desired advantage of reducing design iterations by allowing the designer to investigate the effects of parameter changes, without the risk of expensive tooling costs. Some successful validation of the numerical modelling of the cold roll forming process can be found in literature, in particular when analysing the strain distribution across the material or comparing the final rolled profile geometry. However, cold roll forming is a continuous process and no one has published work on the measurement of the profile on a pass to pass basis, in particular, the three dimensional geometry of the profile. Experimental trials were carried out to obtain a 3D point cloud model of the top surface of a roll formed section. This investigation aimed to quantify how accurate FE simulation may be in relation to physical data.