Determination of Buckling Limit of Strain in Cold Roll Forming through Finite Element Analysis

In this study, Buckling Limit of Strain (B.L.S.) is introduced as one of the most important limiting factors in cold roll forming process. B.L.S. is calculated by the finite element procedure. Then for two particular processes with existing analysis and experimental results, B.L.S. has been determined and evaluated. LUSAS 12.3 is used for finite element analysis. The results show that when buckling of the sheet metal is the limiting factor, B.L.S. is in good agreement with practical limits. It has also been shown that flower pattern can be well predicted when B.L.S. is obtained and this idea is another new outcome from this study. Using this criterion to define and determine B.L.S. and to design the flower pattern is a new concept accomplished for the first time. Keywords: Cold Roll-Forming, Nonlinear Finite Element Analysis, Local Buckling