Computer simulation of U-channel for under-rail roll forming using rigid-plastic finite element methods

Cold-roll forming (CRF) is a well-known process used to manufacture long sheet metal products with constant cross-section. This process makes it possible to manufacture intricate sheet metal products which cannot be made through the press process. It is a very important process in many industrial fields to increase the application. However, the roll forming process is a difficult process because of the time and cost needed to prevent defects in the manufactured products. In order to solve this difficulty, computer analysis using rigid-plastic finite element method is being studied. The computer analysis method allows predicting final shapes and defects of the products through simulation and efficiently manufacturing the products. In this paper, the under-rail composed of three members is designed and the roll forming process is simulated. The under-rail is a relatively unsophisticated mechanism that has rectilinear reciprocating motion. A flow stress equation on SCP-1 is formulated through a tensile test. The flower pattern of the upper member in the under-rail is designed as two types. The roll forming process is estimated using SHAPE-RF software. The longitudinal strain and the numerical magnitude of camber and bow are predicted from the results of the simulation, and qualities of the upper member formed by two types of flower patterns are compared.