Manufacturing of vehicle seat track with roll forming process and simulation by using finite element method

Roll forming is a cold forming process which specialized in the production of profile sheet metal parts. Process is becoming more popular in recent years due to its flexibility in range of products by additional operation steps and capability of producing advanced high strength steels. In this study design criteria's for roll forming line design, blank development methods, specific failure modes defined, forming simulations and prototype production studies are executed. Due to its bendability characteristics, complex phase steel (800CP) is used for simulation and prototype production. Plastic strains are investigated in simulation results and associated with process specific failure modes. After the evaluation of the results, correlation of simulation and prototype profile sections are completed.