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Finite Element Analysis of Flexible Roll Forming of Height Variable Profiles Made of Advanced High Strength DP980 Steel

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Abstract:

In the present study, the technical feasibility of manufacturing a height-variable profile from an advanced high-strength steel (AHSS) sheet using the roll forming process was investigated through finite element analysis (FEA). The study focused on the production of a cross member used in a B-segment passenger vehicle. For this purpose, the kinematics of the forming rolls in both the height and longitudinal directions were derived and integrated into the finite element model. The sheet metal was modeled using both shell and solid (3D) elements. These two different modeling strategies were evaluated in terms of the formed profile geometry. The results demonstrated that the manufacturing of the selected cross member is feasible with the derived roll kinematics. Additionally, it was observed that the use of shell elements led to higher deviations from the desired geometry compared to solid elements. The analyses are planned to be validated experimentally in the next phase of the study.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

277-284

DOI:

https://doi.org/10.4028/p-I1ojoL

Citation:

Cite this paper

Online since:

April 2026

Authors:

Mehmet Okan Görtan*, Ümit Türkmen, İlker Kuzucu, Elif Çivisöker, Rahman Ervan

Keywords:

Advanced High-Strength Steel, Finite Element Analysis, Flexible Roll Forming, Height-Variable Profiles

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