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Analysis of shape defects during flexible roll forming of steel/aluminum double-layered blanks

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Abstract

Flexible roll forming is an advanced sheet-metal-forming process that allows the production of parts with variable cross-sections. Double-layered blanks can have enhanced properties such as a high stiffness-to-weight ratio and high corrosion resistivity when combined with suitable materials. However, in the flexible-roll-forming process of double-layered blanks, additional shape defects and interface delamination can occur owing to their inhomogeneous mechanical properties compared with those of single-layered blanks. In this study, investigations on shape defects generated during the flexible-roll-forming process of steel/aluminum double-layered blanks were performed. Shape defects such as web-war**, wrinkling, and delamination at the interface were investigated on three different blanks with trapezoidal, convex, and concave shapes. The results show that the process-induced longitudinal strains significantly affect the occurrence of shape defects. Moreover, the longitudinal strains strongly depend on the blank shapes, their stacking order, and mechanical properties of the constituent layers.

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Funding

This research was supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) and funded by the Ministry of Education (No. 2016R1D1A3B03931174).

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  1. School of Mechanical Engineering, Pusan National University, 30 Jangjeon dong, Geumjeonggu, Busan, 609-735, Republic of Korea

    Young Yun Woo, Il Yeong Oh, Tae Woo Hwang & Young Hoon Moon

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Correspondence to Young Hoon Moon.

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Woo, Y.Y., Oh, I.Y., Hwang, T.W. et al. Analysis of shape defects during flexible roll forming of steel/aluminum double-layered blanks. Int J Mater Form 13, 861–872 (2020). https://doi.org/10.1007/s12289-019-01504-4

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