Roll Form Process Analysis Using the Explicit Solution Method

In the contemporary automotive industry, the focus on sustainability has driven the need for lighter, more energy-efficient, and environmentally friendly vehicles. High-strength materials play a pivotal role in this effort, enabling the production of lightweight yet durable components that reduce energy consumption and emissions. With the growing adoption of electric vehicles, lightweight design has become even more critical to balance battery weight and extend driving range while maintaining structural integrity. In this context, the roll forming process offers an optimal manufacturing method for producing high-strength materials with complex cross-sectional profiles. However, the use of ultra-high-strength materials introduces additional challenges due to their higher yield strength, such as increased springback, tool wear, and greater sensitivity to thinning and cracking. These challenges not only complicate production but also require precise simulation to predict and mitigate defects. Additionally, calculation time plays a critical role in industrial applications, where fast and accurate simulations are essential to reduce development cycles and meet production deadlines. This study analyzes the roll forming process using the explicit solution method in LS-DYNA. The study focuses on modeling material deformation, elastic recovery, and contact interactions. The results demonstrate that the explicit solution method effectively captures the deformation characteristics of the roll forming process while offering computational efficiency, providing valuable insights for process optimization and predictions.