A Study on Flexible Roll Formed Products Accuracy by Means of FEA and Experimental Tests

Flexible roll formed profiles usually have got highly warped webs if they are manufactured without any supporting tools or process measures. In this paper different methods to improve the accuracy of flexible roll formed parts are described and studied on the basis of a hat‐profile. A new self‐adjusting blank holder system is demonstrated and its potential to reduce warping is experimentally and numerically analyzed. Furthermore the influence of over‐bending the profile’s flange to affect the characteristic strain distribution is studied by means of numerical simulation.