Development and verification of a one-step-model for the design of flexible roll formed parts

The flexible roll forming process, developed at the PtU in Darmstadt, enables the production of profiles with a variable cross section lengthwise. This new forming process offers high flexibility because it is numerically controlled. Proving the feasibility of each new geometry requires either FE analyses or laboratory tests. To shorten this time-consuming lay-out method, an analytic one-step-model was developed. This model uses the results of FE analyses and basic mechanical approaches as input data for the lay-out of flanging processes. The input for the one-step-model consists of relevant geometrical and material data to specify the flexible roll-formed profile and to perform therewith a quick feasibility check for new profile geometries.