Finite Element Study on Chain-Die Forming of an AHSS Channel with Variable Depth

A novel manufacturing technology called chain-die forming was in recent years proposed by Dr. Ding as an alternative to conventional roll forming. Mainly applied in the automotive industry, its prolonged deformation range enables the forming of advanced high strength steels (AHSS) with considerably reduced residual strain, which enables an adequate response to the increasing market requirements of this industry. In this paper, the finite element simulation of chain-die forming an AHSS channel with variable depth is performed. For more accurate predictions, the Bauschinger effect is well considered through the Chaboche hardening model implemented. The residual plastic strain and thickness distributions of the U shaped variable-depth profile are numerically evaluated. The forming limit at a critical zone is analyzed and the predicted magnitude of springback after forming is also calculated. The results portray the forming feasibility and strength of the chain-die forming technology as a valid alternative solution to stamping and roll forming, which are commonly used methods to manufacture such products. In one pass, a complete profile is achieved as opposed to roll forming, with no product defect such as wrinkling or cracking with limited springback development.