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Finite Element Simulation of Chain-Die Forming U Profiles with Variable Cross-Section

Roll forming has been widely used to manufacture constant cross-section products because of high quality, efficiency and low cost. It is quite epidemic in producing automobile parts made of advanced high strength steels (AHSS) nowadays. However, with the development of the vehicle industry and diversity of the products, variable cross-section profiles have attracted more and more attention. The traditional roll forming technique is difficult to meet the requirements. Chain-die forming which was introduced in recent years makes it possible. Chain-die forming is an extension of roll forming and its key characteristic is enlarging the rotation radii of the moulds, by which the deformation zone is extended. The study focused on the finite element simulations of Chain-die forming U profiles with variable cross-section, including variable width and height. The feasibility of Chain-die forming producing variable cross-section products was verified by the perfect simulation results. The advantage of Chain-die forming was that there was no need to design the intermediate moulds except the finished-profile ones, which reduced the mould quantity immensely. Then the cost was lower.