Numerical Investigation of Cold Roll-Forming Process for Three-Layer Metal Sheets and Al/ABS/Al Composites

Abstract

The cold roll-forming process is a continuous technique used to shape metal strips into desired cross-sectional profiles without altering the sheet thickness, achieved by passing the strip through a series of rotating rollers. Multi-layer metal and composite sheets offer unique properties, combining high strength with corrosion resistance. This study focuses on numerically investigating the cold roll-forming of three-layer metal sheets and Al/ABS/Al composites. Utilizing ABAQUS finite element software, the research examines the influence of layer thickness ratios on key parameters such as springback, edge longitudinal strain, thickness variation in the bend area, and energy requirements. Findings indicate a significant increase in sheet thickness reduction with ABS core thickness below 2 mm. Decreasing Acrylonitrile Butadiene Styrene (ABS) core thickness at the forming stage reduces sheet stretching in the bending area, thereby mitigating thinning in that region.