A study of forming a right-angled channel section in one pass by Chain-die Forming
Chain-die Forming, as a replacement forming method to roll forming, has been proposed and developed recently to manufacture long and straight sheet metal products. Chain-die Forming has the advantages of lower redundant strains during forming and nearly zero residual stresses in the product which makes Chain-die Forming superior to roll forming. This study further explores the potentials of the new method. In this paper, this newly developed forming method, Chain-die Forming, is further studied, particularly in forming a right-angled channel section in one pass. In this study, the specially designed die pairs are introduced to optimize the forming process in order to control the occurrence of redundant strain components such as the longitudinal strain which causes the edge wave and longitudinal curvature. The die-profile, of constant radius is particularly studied theoretically, and with FEA numerical simulation and strain gauge measurement. It can be concluded that using Chain-die Forming to form a right-angled channel section in one pass is possible, and can provide a uniform longitudinal strain distribution. Also, Experimental study shows the longitudinal strain is at a lower level and matches with the FEA study.