Validation of complex product geometry from finite element data of the cold roll forming process

Project aim

The overall aim is to close the knowledge loop within Hadley Group between the following stages: the design of tooling for a new profile and the commissioning of tooling prior to production. It is through understanding the role of FE that this is to be achieved.

Project background

This project is in collaboration with Hadley Group, Birmingham, the largest independent manufacturer of cold-rolled metal sections and profiles in the UK. Hadley Group implemented FE simulations in 2009 to assist tooling designers in making design decisions, traditionally made through an empirical approach. Through the use of FE, the tooling designer can investigate the effects of certain parameter changes within the forming process without the risk of expensive tooling costs. Whilst the designers recognise that the design of profile geometry has improved via the use of the software, the global geometry of the linear product still causes significant problems during commissioning, resulting in online tooling modifications, downtime, and cost. In short, FE has proved to be accurate in predicting the forming strategy of a profile but is poor at predicting when forming defects may occur.