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<p>Traditional flat-edge alternating cold roll forming of high-strength steel octagonal tubes often causes severe and non-uniform corner springback. This defect occurs due to stress variations across forming passes. This study proposes an integrated synchronous deformation process to mitigate this issue. We employ S550GD high-strength steel. We also combine finite element simulation with an orthogonal experimental design to achieve high-precision forming control. Identified key influencing factors include the forming strategy, stand spacing, roll profile offset, and compression coefficient. A three-factor, three-level orthogonal analysis evaluated the springback angle. The angle decreases as roll profile offset and compression coefficient increase. However, the angle shows a non-linear trend with greater stand spacing, initially increasing and then decreasing. Range analysis determined the optimal parameters. These include a stand spacing of 450&#xa0;mm, a roll profile offset of 0.01&#xa0;mm, and a compression coefficient of 4%. Industrial trials validated these optimized parameters. The results demonstrated successful control over springback inhomogeneity. The average springback angle decreased from 2.025° to 0.5969°, representing a significant 70.4% reduction. This study provides a viable process solution and a theoretical foundation for the precision cold roll forming of complex high-strength steel sections.</p>

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Integrated synchronous cold roll forming for high-strength steel octagonal tubes with high-precision forming control

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Yu-cheng Mao,
  • Ning Kong,
  • Xiao-li Liu,
  • Chong Yuan,
  • Yong-liang Dong,
  • Rui Fang,
  • Xu-long Guan

摘要

Traditional flat-edge alternating cold roll forming of high-strength steel octagonal tubes often causes severe and non-uniform corner springback. This defect occurs due to stress variations across forming passes. This study proposes an integrated synchronous deformation process to mitigate this issue. We employ S550GD high-strength steel. We also combine finite element simulation with an orthogonal experimental design to achieve high-precision forming control. Identified key influencing factors include the forming strategy, stand spacing, roll profile offset, and compression coefficient. A three-factor, three-level orthogonal analysis evaluated the springback angle. The angle decreases as roll profile offset and compression coefficient increase. However, the angle shows a non-linear trend with greater stand spacing, initially increasing and then decreasing. Range analysis determined the optimal parameters. These include a stand spacing of 450 mm, a roll profile offset of 0.01 mm, and a compression coefficient of 4%. Industrial trials validated these optimized parameters. The results demonstrated successful control over springback inhomogeneity. The average springback angle decreased from 2.025° to 0.5969°, representing a significant 70.4% reduction. This study provides a viable process solution and a theoretical foundation for the precision cold roll forming of complex high-strength steel sections.