A parametric study on forming length in roll forming

A simulation program has been developed in order to examine the roll forming process. The program is based on the three-dimensional finite element analysis of shape and roll forming under kinematically steady-state condition. In this study, the forming length of the strip in the roll forming process was estimated in consideration of some factors such as material properties, strip thickness, roll diameter, roll velocity, and the deformation of the material that influence the forming length decisively. The sensitivity of the forming length to these factors was considered, and the interaction between factors that affect the forming length was considered also. To verify the reliability of the simulation program, the simulated results for longitudinal strain were compared with experimental results available in the literature. It was concluded that the work-hardening exponent plays a major role in the forming length of the pre-deformed strip.