Localized edge buckling in cold roll-forming of circular tube section

Finite element simulation is utilized to predict ‘local edge buckling’, as a limiting factor in cold roll-forming of circular tube section. The importance of edge buckling as a potentially limiting factor for this type of section is described, followed by a finite element analysis of the effect of increasing the profile angle in the first station, on the straightness of the strip edge between the first and the second stations. Simulation results showed that if the profile angle in the first station exceeds a particular limit, reverse bending applied by the rolls of the second station may induce local edge buckling. All simulations made use of the explicit version of ABAQUS 6.4.