Research on longitudinal bowing defect of aluminum alloy plate in roll-forming asymmetric corrugated channels

Longitudinal bowing defect (LBD) is commonly produced during the continuous roll forming of materials, which directly affects the quality of the formed products. The asymmetric corrugated channels (ACCs) have a large number of channels and are subjected to the pressure of asymmetric rollers. Therefore, the control of LBD is more complex compared to single channel during the roll forming. To address the LBD of aluminum alloy plate in roll-forming ACCs, a finite element model with 10 forming passes is firstly established for numerical simulation. Then the mechanism of longitudinal bowing is analyzed, and the influence of various forming parameters on the defects is investigated. The results indicate that the roll diameter and the number of forming passes significantly affect LBD, while other parameters exhibit a relatively minor impact. Finally, an optimal forming scheme is derived. Both the simulation and experiments have shown that the optimized scheme can significantly reduce the forming defects. Thus, it can be used to control the LBD in the roll-forming ACCs.