Parametric optimization of linear roll-hemming process for metal sheets

Abstract

The present work, focus on the parametric optimization of

geometric parameters for Roll Hemming process. Here, the

parameters of interest are the Roller radius, the angle for

pre-hemming stage and the fillet radius. The main objective

is to improve the quality parameters of the process: Roll-In,

Roll-Out and wrinkling. Furthermore, a comparison between

results generated, in numerical and experimental studies, with

optimum and non-optimal parameters, is presented. Finite

Element Analysis (FEA) Software, ANSYS Workbench 15® was

implemented for numerical simulation of the process. For

the experiments, a 6 degree of freedom (DOF) NACHI SRA210

industrial manipulator was used. From numerical results, 2

Rollers were developed with optimum (10.18 mm of radius) and

non-optimal (25 mm of radius) parameters. Multiple tests of

roll hemming in straight paths were performed on several 0.9

mm thick Aluminum sheets 6011 (120 x 100 mm2). Similar to

simulation, the analysis of the obtained results shows that the

Roller with optimum parameters generates the best quality in

hemmed samples.