Determination of buckling limit of strain in cold roll forming by the finite element analysis

In this study, “buckling limit of strain (BLS)” is introduced as one of the most important limiting factors in the cold roll forming process. BLS is calculated by the finite element method. Then for two particular processes with existing analytic and experimental results, BLS has been determined. LUSAS 12.3 is used for the finite element analysis. The results show that when strength of sheet metal is the limiting factor, BLS has a good agreement with practical limits. It has also been shown that the flower pattern can be predicted well when BLS is known. Definition and determination of BLS and design of flower pattern by this criterion are new concepts and have been achieved for the first time.