International Journal For Multidisciplinary Research

E-ISSN: 2582-2160   •   Impact Factor: 9.24

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Understanding and Controlling End-Flare Error in Rollforming

Author(s) Mr. Himmet Ufuk KULAVUZ, Prof. Dr. Ismail BOGREKCI, Prof. Dr. Pinar DEMIRCIOGLU
Country Turkey
Abstract Roll forming is a continuous cold forming operation in which a strip of material is progressively shaped into a desired cross-sectional profile in a series of roll stations. It is preferred in high-volume production environments because of the high production rates and low labor needs. Its use in low-volume production contexts is, however, restricted by lengthy setup times. There is plastic deformation of the material in the process of roll forming that leads to residual stresses, which result in permanent geometrical transformation. This transformation can be in the form of defects like bowing, twisting, waviness, loss of straightness, and end flare that become most apparent after the cutting operation. End flare is a critical defect that undermines the performance of profiles, particularly in assembly-dependent uses in several industries like automotive, electronics, home appliances, horticulture, and photovoltaic systems. The aim of the study is to describe the mechanisms underlying the formation of end flare in roll-formed U-section profiles. There is a marriage of finite element analysis and experimental confirmation used to study the defect with the final goal of seeking and suggesting viable solutions for minimizing its occurrence.
Keywords Roll Forming, End Flare, Residual Stress, Geometric Defects, U-Section Profiles.
Field Engineering
Published In Volume 7, Issue 3, May-June 2025
Published On 2025-06-15
DOI https://doi.org/10.36948/ijfmr.2025.v07i03.48105
Short DOI https://doi.org/g9qqp4
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