Cold Roll Forming Process Design for Complex Stainless-Steel Section Based on COPRA and Orthogonal Experiment

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes
• Mechanical Engineering

Background:

• Cold roll forming enables fabrication of complex product profiles.
• Optimizing cold roll forming parameters is crucial for enhancing product quality and precision.
• Stainless steel SUS301L-ST is used for complex sections, such as side shields.

Purpose of the Study:

• To analyze the cold roll forming of a complex stainless steel section (SUS301L-ST).
• To investigate the effects of various parameters on longitudinal strain.
• To propose a floating roll device for asymmetric and deep complex sections.

Main Methods:

• Established a 3D finite element model using COPRA software.
• Employed an orthogonal experimental design to study parameter influences.
• Investigated inter-roll distance, friction coefficients, diameter increments, and line velocities.

Main Results:

• Diameter increment was found to have the most significant impact on reducing maximum longitudinal strain.
• Optimal inter-roll distance is necessary; too small hinders elastic deformation release, too large causes displacement and cost issues.
• Increased friction reduces strain but can cause surface defects; increased velocity increases strain.

Conclusions:

• Optimal cold roll forming parameters were determined for the analyzed complex section.
• The findings provide a theoretical foundation for practical production of high-precision stainless steel components.
• A floating roll device was proposed for handling asymmetric and deep complex sections.