Basics of linear flow splitting

Linear flow splitting enables the forming of bifurcated profiles in integral style out of sheet metal without joining, lamination of material or heating of the semi-finished part. The new roll forming process uses obtuse angled splitting rolls and supporting rolls to increase the surface of the band edge. The high hydrostatic compressive stresses induced in the local forming zone during the process lead to an increased formability of the material and enable the realization of large strains. Produced parts are characterized by increased stiffness, high surface hardness and low surface roughness. The basic principle of the process and the occurring phenomena are described in this paper.