Numerical simulation of cold roll-forming processes

3D finite element analysis is employed to simulate a cold roll-forming process. Numerical results of longitudinal strains and displacement trajectories are compared with experimental results available in the literature. Through a parametrical study, significant impacts of the yield limit and the work-hardening exponent on the product quality are observed, whereas forming speed and friction at roll-sheet interface appear to play a minor role. (C) 2007 Elsevier B.V. All rights reserved.