Design and realisation of flexible T-profile rolling

A new process called flexible T-profile rolling has been developed to produce T-profiles with different load-adapted thicknesses along their length. This process provides an environmentally friendly and resource-efficient production method for e.g. aluminium aircraft stringers. This paper outlines the fundamentals of designing the roll stand, the rolls themselves, and the roll movement curves, which are based on preliminary numerical investigations. The new process is then validated experimentally for the first time. It demonstrates that target thicknesses and curves can be effectively achieved through flexible T-profile rolling with multiple passes and thickness transitions. The thickness of the T-profile was reduced by 50%, from 3 mm to 1.5 mm, across the entire cross-section in three rolling passes. Experiments and simulations of the new rolling process show good agreement. Furthermore, the hardness properties achieved in the material are homogeneous across the cross-section of the rolled profiles. However, despite the use of a straightening roll after the rolling gap, the profile still exhibited a small vertical bow due to the inhomogeneous distribution of longitudinal strain. • A new process, flexible t-profile rolling, has been developed. • A numerical model of flexible t-profile rolling has been experimentally validated. • The thickness of the web and flange can be reduced by up to 50% along their length. • Spreading of the profile can be neglected.