Experimental and numerical prediction and comprehensive compensation of springback in cold roll forming of UHSS

Ultra-high-strength steels (UHSS), for instance, dual phase (DP) and martensitic steels, get growing challenges in strip metal forming processes of car industry manufacturing to achieve lightweight and improve passenger security. Predict and compensate for springback is still a major problems to be solved in cold roll forming (CRF) for complex section materials. In this study, the springback performance UHSS in cold roll forming is discussed by simulation and experimental methods. At the same time, one 3D FEA model was established to analyze the CRF process by COPPA RF and MSC MARC, in which planar swift’s model, anisotropic Hill’s 48 model, and Yid2000-2d model in the company with Yoshida-Uemori kinematic hardening pattern were investigated. Automobile threshold section CRF experiment and springback evaluation carried out through the comparison of numerical results. Considering Yoshida-Uemori kinematic hardening, the anisotropic Yid2000-2d model improves the springback prediction accuracy in CRF car threshold section in comparison with other models. The improved model is used to compensate the springback of product. A new method is proposed, which takes into account angle overbending compensation (AOC), small radius compensation (SRC), and revere-bending compensation (RBC) based on roll shape design. The method, which we call “USTB-Durable Integration of Springback Control (UDI),” is general for it considers the fact radius and angle would occur during springback. Compared with the AOC, SRC, and RBC method, the new method has higher precision especially for the springback compensation of ultra-high-strength complex section in CRF. The researchers are expected to conduct design engineer to calculate and compensate the springback trend before applying roller design to actual production.