A first approach towards in-line shape monitoring and control in flexible roll forming automotive components

Abstract. Flexible Roll Forming (FRF) enables the manufacture of long and complex parts for automotive applications. In this paper, a frame rail component is successfully flexible roll formed from Advanced-High-Strength-Steel (AHSS). The component has a variable width and depth contour and shows variable springback over the length. Laser sensors were implemented to monitor the springback angle over the length of the part between forming steps. This was followed by a variable overbending pass to compensate for springback. Based on this, a flexible in-line shape control was developed and validated experimentally. in trials of three approaches to compensating for springback in a single geometry made in a single material, the springback of one approach was lower, but we cannot yet predict how this applies in other parts, or whether our compensation approach has other unwanted effects on other component features. The results of this study suggest that FRF in combination with inline shape control can achieve complex component shape quality standards that suit automotive applications. However, this study was limited to one single material condition and part shape and further studies are needed to validate the general applicability of the procedure to other workpiece geometries and material conditions.