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Finite element analysis of roll forming process for AZ31B magnesium alloy tube

Abstract Most magnesium tubes are produced by extrusion, however roll forming could be another process to produce magnesium tubes since magnesium alloy sheet has become popular. In this study, to design the roll forming line for magnesium alloy AZ31B tube, finite element analysis was conducted to determine the design solution and to predict any forming problems. The results of the analysis showed that the finite element method could be a good tool to determine the angular velocity of each roll stand, which is an important point in the design of the roll forming process. The deflection of the front end of the strip at the exit of #1 roll stand, which is an obstacle in roll forming, was predicted and the way to control it was investigated. According to the simulation results of the given roll forming design, roll forming at room temperature is not possible, not because of poor formability of the magnesium alloy but because of its high level of springback.