Rollform prosesinde kesim sonrasi ağiz açikliği hatasinin incelenmesi

The roll forming process is defined as the step-by-step cold forming of a strip material into the desired cross-sectional geometry using forming rolls, referred to as stations. Roll forming is preferred in high-volume production due to its higher production speed and lower labor requirements compared to other cold forming methods. However, in low-volume production, it is less favored because of the long die setup times. During the roll forming process, the strip material undergoes plastic deformation during shaping, leading to the formation of residual stresses and resulting in permanent deformations within the material. These permanent deformations cause various geometric defects in the produced profiles, such as loss of straightness, bowing, twisting, waviness, and end flare after cutting. Profiles manufactured by roll forming are used in many sectors, including automotive, greenhouse, electrical-electronics, white goods, and solar energy systems. Particularly, end flare defects occurring after cutting significantly affect the functionality of profiles in assembly applications. Within the scope of this thesis, the formation mechanisms of end flare defects after cutting will be investigated; focusing on a U-section profile, the end flare defect will be analyzed using the finite element method, and practical solution methods aimed at minimizing the defect will be explored.