Design Of Cold Roll Forming For Special Shaped Section In Cab

In recent years, Chinese automobile manufacturing industry grows rapidly and has become one of the critical industries of the national economy. The development and manufacturing of the automobile should prefer the material with simple, convenient, efficient, good performance, energy saving, green and etc.. As a kind of green material, the cold-formed steel has the optimized section, good mechanical performance and high utilization ratio, which will be applied in the automotive industry more widely. However, due to the limitations from technology, processes, equipment and other reasons, the related enterprise shave to face the long development cycle, high investment and trial risk during the development process of cold-formed steel product. This paper focuses on researching the design, development and manufacturing of cold-formed steel for the engineering vehicle cab. With reference to the relevant industry experience, the forming angle is optimized based on the principle of cold bending forming by using ABAQUS. Finally, the forming and rolling system is designed and verified, which can guarantee that the quality of the product. It is significant to the development and production of profiled material in automotive industry.This paper first analyzes the cold-formed steel forming principle, identifies the length of gentle transition zone during forming and proposes the minimum bending radius calculation method. Based on the proposed method, the strip forming rules of cold rolling process can be understood systematically, and the deformation performance can be predicted, which can help to reduce the blindness in the process and profile design.Subsequently, the cold rolling process is studied. The technological factors, such as: deformation length, frame spacing, frame number, shaft and bottom diameter of roller, forming the bottom line, forming speed have been analyzed quantitatively. Additionally, the profile design foundation, procedure, molding method and principle are proposed.Finally, in term of the cold forming process and the company's existing equipment, the forming angle is optimized based on the theoretical research by using ABAQUS software. Then the product Roller flower figure is completed for the engineering vehicle cab. In the end, the rolling profile of the profiled material used in the engineering vehicle cab is designed, and the corresponding product is manufactured.The results show that the developed process and rolling system satisfies the requirement of the cold forming steel for engineering vehicle cab.