Design and Simulation of Roll Forming Process for Corrugated Sheet Metal of Subway Train Based on COPRA

GAO Yuxia; LIU Ning; ZHANG Zhimin; JIN Siyu; SUN Jun

doi:10.3969/j.issn.1674-6457.2026.03.025

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (3) : 251-260. DOI: 10.3969/j.issn.1674-6457.2026.03.025

Advanced Manufacturing Technology and Equipment

Design and Simulation of Roll Forming Process for Corrugated Sheet Metal of Subway Train Based on COPRA

GAO Yuxia¹, LIU Ning^1,*, ZHANG Zhimin², JIN Siyu³, SUN Jun³

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Abstract

The work aims to conduct an in-depth study on common issues such as residual internal stress and edge waves that frequently occur during the cold roll forming of subway corrugated sheets to eliminate the corrugated defects generated during the roll forming process of corrugated sheets. Based on the elastic-plastic deformation theory and the professional software COPRA, a finite element model for the roll forming process of wide corrugated sheets that met production standards was established. Considering the mechanical properties of the material and the actual influencing factors of the process, finite element simulations for each forming pass were performed to predict potential problems in advance. Improvements were subsequently made by adjusting the process parameters and optimizing the roller design. The simulation analysis results indicated that the stress and strain values in the 7th, 8th, 11th, 12th, 15th, and 16th passes exceeded the material limits, resulting in excessive local stress in the strip and inducing tensile plastic deformation. Based on the DTM analysis results, the forming angles of these six passes were reallocated. With an initial sheet thickness of 0.6 mm, the material at the bending corners experienced thinning after 16 passes of roll forming. The minimum thickness reached 0.517 mm, representing a thinning rate of 13.83%, which was well within the allowable engineering range for sheet thinning. A quantitative analysis of the safety factors showed that the strain safety factor reached 2.39 and the stress safety factor was 1.26, thereby verifying the safety of the process design. Furthermore, the relative errors of key indicators between the simulation predictions and production measurements were all less than 10%, indicating that the simulation model possessed high prediction accuracy. By optimizing the roller design and adopting mold debugging analysis alongside corresponding solution strategies, production verification is successfully carried out on the cold roll forming unit. This successfully resolves the quality defects of wide corrugated sheets during the roll forming process for subways. The research method provides scientific guidance for roll forming, serving not only as a reliable basis for the process design of wide corrugated sheets but also as a valuable reference for the process optimization of similar products.

Key words

cold roll forming / corrugated plate / COPRA / roll pattern / roll / modal simulation

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GAO Yuxia, LIU Ning, ZHANG Zhimin, JIN Siyu, SUN Jun. Design and Simulation of Roll Forming Process for Corrugated Sheet Metal of Subway Train Based on COPRA[J]. Journal of Netshape Forming Engineering. 2026, 18(3): 251-260 https://doi.org/10.3969/j.issn.1674-6457.2026.03.025

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Funding

Scientific Research Project of Jilin Provincial Department of Education in 2024 (JJKH20241782KJ); Natural Science Foundation of Jilin Province (20260102277JC); 2024 “Science and Technology Innovation Commissioner (Vice President of Science and Technology Innovation)” Project of Jilin Provincial Department of Science and Technology