Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming
The cold roll forming process is broadly used to produce a specific shape of cold-roll formed products for their applications in automobiles, aerospace, shipbuilding, and construction sectors. Moreover, a proper selection of strip thickness and forming speed to avoid fracture is most important for m...
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MDPI AG
2021-01-01
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| Online Access: | https://www.mdpi.com/1996-1944/14/2/470 |
| _version_ | 1797409610478387200 |
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| author | Mohanraj Murugesan Muhammad Sajjad Dong Won Jung |
| author_facet | Mohanraj Murugesan Muhammad Sajjad Dong Won Jung |
| author_sort | Mohanraj Murugesan |
| collection | DOAJ |
| description | The cold roll forming process is broadly used to produce a specific shape of cold-roll formed products for their applications in automobiles, aerospace, shipbuilding, and construction sectors. Moreover, a proper selection of strip thickness and forming speed to avoid fracture is most important for manufacturing a quality product. This research aims to investigate the presence of longitudinal bow, the reason behind flange height deviation, spring-back, and identification of thinning location in the cold roll-forming of symmetrical short U-profile sheets. A room temperature tensile test is performed for the commercially available AA5052–H32 Al alloy sheets using Digital Image Correlation (DIC) technique, which allows complete displacement and strain data information at each time-step. The material properties are estimated from the digital images using correlation software for tested samples; the plastic strain ratios are also calculated from samples at 0°, 45°, and 90° to the rolling direction. The tested sample’s surface morphology and the elemental analysis are conducted using scanning electron microscopy (SEM) method and energy-dispersive X-ray spectroscopy (EDS) analytical technique combined with element mapping analysis, respectively. The cold roll forming experiments are systematically carried out, and then finite element analysis is utilized to correlate the experiment with the model. The performed cold roll forming numerical model outcome indicates a good agreement with the experimental measurements. Overall, the presented longitudinal strain was observed to influence the geometry profile. The spring-back is also noticed at the profile tail end and is more pronounced at high forming speed with lower strip thickness. Conversely, while the forming speed is varied, the strain and stress variations are observed to be insignificant, and the similar results also are recognized for the thinning behavior. |
| first_indexed | 2024-03-09T04:17:07Z |
| format | Article |
| id | doaj.art-826e0aa686694ceba706b91551bab0b0 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-09T04:17:07Z |
| publishDate | 2021-01-01 |
| publisher | MDPI AG |
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| series | Materials |
| spelling | doaj.art-826e0aa686694ceba706b91551bab0b02023-12-03T13:52:12ZengMDPI AGMaterials1996-19442021-01-0114247010.3390/ma14020470Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll FormingMohanraj Murugesan0Muhammad Sajjad1Dong Won Jung2Department of Mechanical Engineering, Jeju National University, Jeju-Do 63243, KoreaDepartment of Mechanical Engineering, Jeju National University, Jeju-Do 63243, KoreaDepartment of Mechanical Engineering, Jeju National University, Jeju-Do 63243, KoreaThe cold roll forming process is broadly used to produce a specific shape of cold-roll formed products for their applications in automobiles, aerospace, shipbuilding, and construction sectors. Moreover, a proper selection of strip thickness and forming speed to avoid fracture is most important for manufacturing a quality product. This research aims to investigate the presence of longitudinal bow, the reason behind flange height deviation, spring-back, and identification of thinning location in the cold roll-forming of symmetrical short U-profile sheets. A room temperature tensile test is performed for the commercially available AA5052–H32 Al alloy sheets using Digital Image Correlation (DIC) technique, which allows complete displacement and strain data information at each time-step. The material properties are estimated from the digital images using correlation software for tested samples; the plastic strain ratios are also calculated from samples at 0°, 45°, and 90° to the rolling direction. The tested sample’s surface morphology and the elemental analysis are conducted using scanning electron microscopy (SEM) method and energy-dispersive X-ray spectroscopy (EDS) analytical technique combined with element mapping analysis, respectively. The cold roll forming experiments are systematically carried out, and then finite element analysis is utilized to correlate the experiment with the model. The performed cold roll forming numerical model outcome indicates a good agreement with the experimental measurements. Overall, the presented longitudinal strain was observed to influence the geometry profile. The spring-back is also noticed at the profile tail end and is more pronounced at high forming speed with lower strip thickness. Conversely, while the forming speed is varied, the strain and stress variations are observed to be insignificant, and the similar results also are recognized for the thinning behavior.https://www.mdpi.com/1996-1944/14/2/470roll formingAA5052–H32 Al alloysymmetrical short U-profilelongitudinal bowspring-backdigital image correlation |
| spellingShingle | Mohanraj Murugesan Muhammad Sajjad Dong Won Jung Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming Materials roll forming AA5052–H32 Al alloy symmetrical short U-profile longitudinal bow spring-back digital image correlation |
| title | Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming |
| title_full | Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming |
| title_fullStr | Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming |
| title_full_unstemmed | Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming |
| title_short | Experimental and Numerical Investigation of AA5052-H32 Al Alloy with U-Profile in Cold Roll Forming |
| title_sort | experimental and numerical investigation of aa5052 h32 al alloy with u profile in cold roll forming |
| topic | roll forming AA5052–H32 Al alloy symmetrical short U-profile longitudinal bow spring-back digital image correlation |
| url | https://www.mdpi.com/1996-1944/14/2/470 |
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