Determination of structural properties of cold roll formed dimpled steel sections and analysing galling in the forming process
Lead Research Organisation:
University of Sussex
Department Name: Sch of Engineering and Informatics
Abstract
Summary: Dimpled steel sections are cold roll formed by the Hadley group. These dimpled sections have been analysed and it is reported that they can carry more load comparing to the pre-dimpled plain steel sections. Further research on the properties of dimpled steel sections will be conducted; experimental test and finite element analysis will be carried out to obtain design expressions for determining structural properties. Analysis of contact pressure and friction force in the cold roll forming process will also be conducted to eliminate galling.
Partners' roles: The project requires bending and tensile test of structures. Material testing machines are available at Hadley group and test samples will be provided by Hadley group. ANSYS software and HPC facilities are available in the School and the University
The student will visit the Hadley group to understand cold roll forming and dimpling manufacturing process. The student will be trained to use specialist cold roll sheet metal forming simulation software at the company. The student will also be trained on dimpling simulation using ANSYS software and conducting experimental test by the supervisor at the University.
Aims To analyse and determine structural properties of dimpled steel sections manufactured by a cold roll forming process and eliminate tool galling wear in the forming process.
Objectives
1. Derive expressions for determining structural properties of dimpled steel sections (WPs 1 - 3)
2. Derive expressions for determining rotational and linear stiffness of connections of dimpled steel sections (WPs 4 -6 )
3. Analyse tool designs in the cold roll forming process and eliminate galling (WPs 7 - 9)
Partners' roles: The project requires bending and tensile test of structures. Material testing machines are available at Hadley group and test samples will be provided by Hadley group. ANSYS software and HPC facilities are available in the School and the University
The student will visit the Hadley group to understand cold roll forming and dimpling manufacturing process. The student will be trained to use specialist cold roll sheet metal forming simulation software at the company. The student will also be trained on dimpling simulation using ANSYS software and conducting experimental test by the supervisor at the University.
Aims To analyse and determine structural properties of dimpled steel sections manufactured by a cold roll forming process and eliminate tool galling wear in the forming process.
Objectives
1. Derive expressions for determining structural properties of dimpled steel sections (WPs 1 - 3)
2. Derive expressions for determining rotational and linear stiffness of connections of dimpled steel sections (WPs 4 -6 )
3. Analyse tool designs in the cold roll forming process and eliminate galling (WPs 7 - 9)
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/N509784/1 | 01/10/2016 | 30/09/2021 | |||
| 1811807 | Studentship | EP/N509784/1 | 01/10/2016 | 31/03/2020 | David Scholtz |
| Description | The structural properties of dimpled steel as these relate to the structural properties of plain steel have been explored through extensive tensile testing and microstructural examination. The resulting data has formed the basis for expressions derived to facilitate the prediction of the effectiveness of the dimpling process as measured by change in yield strength for any given plain steel source. Following from this, a more appropriate measure of yield strength has been developed. The effects of the application of the dimpling process on the stiffness of steel sheet have also been assessed through the application of finite element methods for plain and dimpled cross-sections. During this research, various finite element simulations have also been developed to facilitate understanding of the material behaviour, thus helping to explain trends identified in the dataset previously noted. These simulations have also been applied to the assessment and novel redesign of the dimple tooth profiles. |
| Exploitation Route | The predictive expressions and the newly proposed measure of yield strength may be used in industry by the supporting company (Hadley Group) to improve production efficiency and more accurately characterise their products incorporating dimpled steel components. The simulations, experimental data (tensile and microstructural), and understanding gained therefrom may be used in both industrial and further academic research on metalforming and the implications of cold roll dimpling of steel and other metals. |
| Sectors | Construction,Manufacturing, including Industrial Biotechology |