Effect of the forming method on part shape quality in cold roll forming high strength Ti-6Al-4V sheet

The primary aim of this study is to explore the potential use of different roll forming methods to reduce springback and part shape defects in the cold roll forming of Ti-6Al-4V sheet and to develop a deeper understanding of the material behaviour of Ti-6Al-4V in the process. For this, experimental roll forming trials and their simulation are performed and a novel constitutive material model based on the homogeneous anisotropic hardening (HAH) approach is used to represent the forming behaviour of Ti-6Al-4V under cold forming conditions. The experimental and numerical results indicate that the constant radius forming method leads to fewer shape defects in the process and reduced springback. A detailed discussion is provided explaining in part the observed trends.