Experimental and numerical analysis on the forming and shearing quality of C-channel steel

The method of cold roll forming, without using the press brake prior, is a kind of plastic forming process which produces the specified cross sections by a series of forming rollers. To measure the forming strain, the experiments adopted a non-contact strain measurement method and compared with the numerical model. A number of process parameters such as forming angle increment (F.A.I), forming velocity and station distance are studied to find the effects on the forming quality. The FEM of 45° die shear system is set up and compared with the experimental results. The effects of shear parameters such as the shear angle and the shear velocity are also discussed. The consequences demonstrate that the 45° die shear system has shear blind zones which have bad shearing quality. The shear velocity has a significant influence on the shear zone length.