Roll forming is a continuous cold forming process that is characterised by high resource efficiency and productivity due to its high process speeds and up to 100% material utilisation. However, fluctuations in product quality often occur in the production of roll-formed profiles. It is assumed that these are due to fluctuations in the process or starting material.

The aim of this thesis is to investigate the influences of various process and material fluctuations on profile quality using FE simulations and experiments. It also aims to analyse how these fluctuations can be detected in the process. The work includes the following work packages, which can best be discussed and, if necessary, adapted in a meeting:

• Development or adaptation of existing FE models
• Introduction of material fluctuations and process instabilities into the simulation models and evaluation of the simulations
• Experimental validation of the simulation results

Research method

Experimental, numerical