Localised edge buckling in cold roll-forming of symmetric channel section

The limit of allowable deformation that can be achieved in a single stage is one of the most important constraints for the design of a roll-forming process. In this paper, finite element simulation is utilized to predict local edge buckling as a limiting factor in the cold roll-forming of a symmetric channel section. To calibrate the finite element simulation, a comparison is made between computed and previously measured longitudinal strain. The simulation results show that during the rolling mill set-up phase, the fold angle in the first station should be kept below a particular limit. Above this limit, reverse bending applied by the rolls of the second station, may induce local edge buckling, which will result in an undesirable product because of the uneven shape of the flange.