Experimental and Numerical Analysis of Fracture on Flexible Roll Forming Process of channel section in Aluminum 6061-T6 sheet

Dadgar Asl, Yaghoub; Sheikhi, Mohammad Morad; Pourkamali Anaraki, Ali; Panahizadeh Rahimloo, Vali Ollah; Hosseinpour Gollo, Mohammad

Experimental and Numerical Analysis of Fracture on Flexible Roll Forming Process of channel section in Aluminum 6061-T6 sheet

Authors

Yaghoub Dadgar Asl ¹

Mohammad Morad Sheikhi

Ali Pourkamali Anaraki ²

Vali ollah Panahizadeh Rahimloo ³

Mohammad Hosseinpour Gollo ³

¹ phd student/shahid rajaee teacher training university

² Associate professor mechanical engineering/shahid rajaee teacher training university

³ Assistant professor mechanical engineering/shahid rajaee teacher training university

Abstract

Today, with the development of technology, industries such as automotive and construction require products with variable cross section. Multiplicity of steps, dimensional limitation and high production costs of the components caused flexible roll forming process used to produce these products. One of the main defects in this process is the fracture phenomenon. The fracture is observed on the bending edges at transition zone that sheet thickness is large compared to the bending radius. In this research the fracture phenomenon is investigated on flexible roll forming process of channel section using ductile fracture criteria. For this purpose finite element simulation of the process using Abaqus software is done. The fracture defect in this process is investigated using six ductile fracture criteria by developing a subroutine. Experimental tests are performed on 27 specimens precut sheet of AL6061-T6, using flexible roll forming machine built in Shahid Rajaee University. By comparing simulation results with experimental results, numerical results were validated. In addition, by comparing the results of ductile fracture criteria with experimental results, the Argon ductile fracture criteria, was chosen as the most appropriate criterion to predict fracture. Also the effects of parameters as sheet thickness, bending radius and bending angle on fracture with argon selected criterion is studied.

Keywords

Flexible roll forming

Fracture defect

Ductile fracture criteria

Finite Element Method (FEM)