Effect of loading pattern on longitudinal bowing in flexible roll forming

The flexible roll forming process can be used to fabricate products with a variable cross-section profile in the longitudinal direction. Transversal nonuniformity of the longitudinal strain is one of the fundamental characteristics of blank deformation in flexible roll forming. Longitudinal bowing is a shape defect caused by transversal nonuniformity of the longitudinal strain. In this study, loading patterns in flexible roll forming are investigated in order to reduce the longitudinal bowing in a roll-formed blank. To analyze the effects of loading patterns on longitudinal bowing, two different forming schedules are implemented. In schedule 1, loading patterns with different bending angle increments are designed under fixed initial and final bending angles. In schedule 2, loading patterns with different initial bending angles under the fixed final bending angle are designed. Our results show that the bowing heights are significantly affected by the loading patterns. The bowing susceptibilities vary with blank shape such as trapezoid, convex, and concave shapes. In addition to the peak longitudinal strain at the respective roll stands, the cumulative longitudinal strain from the initial to final stands is shown to be a reliable index in predicting the tendency of longitudinal bowing.