Finite Element Analysis of roll forming process of aluminum automotive component

Roll forming process is currently used in manufacturing of many automotive components. The material of roll formed product is gradually changed from proper steel to aluminum for reducing the weight of car. The process with aluminum material has many different characteristic to steel and still is not investigated clearly. This paper presents the Finite Element Analysis of roll forming of aluminum automotive component. Many important results, such as distribution of longitudinal strain, analysis of spring back phenomenon, failure in process, or redundant deformation have been obtained. The comparison between process with aluminum and steel is carried out. These results are necessary for determining major factors in optimization procedure of roll forming of automotive component.