Journal of the Korean Society for Precision Engineering (한국정밀공학회지)

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지
DOI QR코드

DOI QR Code

Fundamental Study on the Development of a New Incremental Roll Forming Process for Structural Pipe Manufacturing

구조용 파이프 생산을 위한 새로운 점진적 롤 성형 공정 개발에 관한 기초 연구

  • Son, Jong Youn (Department of Mechanical Engineering, Chonnam National University) ;
  • Yoon, Hee Seok (Department of Mechanical Engineering, Chonnam National University) ;
  • Park, Won Kyun (Research and Development Head Office, Keum Sung Industry) ;
  • Shim, Do Sik (Green Manufacturing Process Technology Center, Korea Institute of Industrial Technology)
  • 손종윤 (전남대학교 기계공학과) ;
  • 윤희석 (전남대학교 기계공학과) ;
  • 박원균 ((주)금성산업 기술개발팀) ;
  • 심도식 (한국생산기술연구원 그린가공공정그룹)
  • Received : 2016.09.13
  • Accepted : 2017.02.09
  • Published : 2017.03.01
Download PDF
⟨ Previous Next ⟩

Abstract

Structural pipe frames are usually manufactured by complex processes, in which a straight pipe with an arbitrary cross-section is prepared via a roll-forming process and then fabricated into three-dimensional shapes by a secondary process. These conventional processes have low productivity. Recently, the inefficiency of the conventional processes has created the need to develop new forming technologies. In this study, a new incremental roll-forming process is proposed. The study is aimed at verifying the feasibility of the proposed process and investigating the fundamental process parameters using finite-element simulations. The result of the simulation demonstrates that the proposed process can be used effectively for cold fabrication of various shapes of structural pipes. In addition, the result of the investigation of parameters shows that the forming amount, number of roll sets, and distance between roll sets are significant factors to be considered in resolving dimensional errors of the product and improving its quality.

Keywords

References

  1. Kim, D. K., Park, S. E., Cho, K. R., Lee, K. H., Kim, K. H., et al., "Development of Manufacturing Technology for Center Floor Cross Member with Roll Forming Process," Proc. of the Korean Society for Technology of Plasticity Conference, pp. 297-300, 2009.
  2. Yun, J. J., Park, D. H., and Kim, K. Y., "The Development of High Strenght Steel on Car Body Part by Roll Forming Process," The Korean Society of Manufacturing Technology Engineers Conference, p. 111, 2011.
  3. Park, J. C., Cha, M. W., Kim, D. G., Nam, J. B., Yang, D. Y., et al., “Investigation of Shape Parameters for a Profile with Variable-Cross Sections Produced by Flexible Roll Forming,” Transactions of Materials Processing, Vol. 23, No. 6, pp. 369-375, 2014. https://doi.org/10.5228/KSTP.2014.23.6.369
  4. Groche, P., Breitenbach, G. V., Jockel, M., and Zettler, A., "New Tooling Concepts for Future Roll Forming Applications," Proc. of IEEE International Conference on Industrial Tools, pp. 121-126, 2003.
  5. Ona, H., "Study on Development of Intelligent Roll Forming Machine," Proc. of International Conference on Technology of Plasticity, pp. 503-504, 2005.
  6. Hiroshi, O., Ryuhou, S., Nagamachi, T., and Hoshi, K., "On Development of Flexible Cold Roll Forming Machine," Proc. of International Conference on Advanced Technology of Plasticity, pp. 2021-2025, 2008.
  7. Chatti, S., Hermes, M., Tekkaya, A. E., and Kleiner, M., “The New TSS Bending Process: 3D Bending of Profiles with Arbitrary Cross-Sections,” CIRP Annals-Manufacturing Technology, Vol. 59, No. 1, pp. 315-318, 2010. https://doi.org/10.1016/j.cirp.2010.03.017
  8. Becker, C., Tekkaya, A. E., and Kleiner, M., "Fundamentals of the Incremental Tube Forming Process," CIRP Annals-Manufacturing Technology, Vol. 63. No. 1, pp. 253-256, 2014. https://doi.org/10.1016/j.cirp.2014.03.009
  9. Hudovernika, M., Kosel, F., Staupendahl, D., Tekkaya, A. E., and Kuzman, K., "Application of the Bending Theory on Square-Hollow Sections Made from High-Strength Steel with a Changing Angle of the Bending Plane," Journal of Materials Processing Technology, Vol. 214, No. 11. pp. 2505-2513, 2014. https://doi.org/10.1016/j.jmatprotec.2014.05.016
  10. Cha, M. H. and Kim, D. G., "Development of Object Parts Using Multi-Directional Roll Forming," Proc. of the Korean Society of Automotive Engineering Conference, pp. 1331-1333, 2012.
  11. Park, J. C., Cha, M. W., Kim, D. G., Nam, J. B., and Yang, D. Y., “Investigation of Shape Parameters for a Profile with Variable-Cross Sections Produced by Flexible Roll Forming,” Transactions of Materials Processing, Vol. 23, No. 6, pp. 369-375, 2014. https://doi.org/10.5228/KSTP.2014.23.6.369
  12. Park, J. C., Lee, S. U., Yang, D. Y., Cha, M. H., and Seong, D. Y., "A Forming Process of Profiles with Variable Cross-Section in Depth Employing Incremental Forming and Local Heating," Proc. of KSPE Spring Conference, pp. 49-50, 2011.
  13. Park, J. C., Seong, D. Y., Lee, S. U., Yang, D. Y., and Cha, M. H., "Development of a New Forming Process to Fabricate Profile with Variable Cross-Section," Proc. of the Korean Society for Technology of Plasticity Conference, pp. 282-285, 2012.