{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,7,3]],"date-time":"2026-07-03T18:23:51Z","timestamp":1783103031581,"version":"3.54.6"},"reference-count":26,"publisher":"MDPI AG","issue":"24","license":[{"start":{"date-parts":[[2023,12,12]],"date-time":"2023-12-12T00:00:00Z","timestamp":1702339200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Beijing Space Vehicle General Design Department of the Chinese Academy of Space Technology","award":["WY-YY\/30508010701JY0011"],"award-info":[{"award-number":["WY-YY\/30508010701JY0011"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>In this paper, a new technology for on-orbit cold forming of space truss rods is proposed. For the cold roll forming process of asymmetric cross sections of thin strips, the effects of roll gap and roll spacing on the forming of asymmetric cross sections of strips were investigated using ABAQUS simulation + experiments. The study shows the following. When forming a strip with a specific asymmetric cross section, the stresses are mainly concentrated in corners 2\/4\/6, with the largest strain value in corner 2. With increasing forming passes, when the roll gap is 0.3 mm, the maximum equivalent strain values are 0.09, 0.24, 0.64 sequentially. Roll gaps of 0.4 mm and 0.5 mm equivalent strain change amplitude are relatively similar, and their maximum equivalent strain values are approximately 0.07,0.15, 0.44. From the analysis of the stress\u2013strain history of the characteristic nodes in corners 2\/4\/6, it can be seen that the stress and strain changes in the deformation process mainly occur at the moment of interaction between the upper and lower rollers, where the stress type of node 55786 shows two tensile types and one compressive type, the stress type of nodes 48594 and 15928 shows two compressive and one tensile type, and the strain of the three nodes is in accordance with the characteristics of plane strain. When the roll gap is about 0.4 mm, the forming of the strip is relatively good. With increased roll spacing, the strip in the longitudinal stress peak through the rollers shows a small incremental trend, but the peak stresses are 380 Mpa or so. When the roll spacing is 120 mm, the longitudinal strain fluctuation of the strip is the most serious, followed by the roll spacing at 100 mm, and the minimum at 140 mm. Combined with the fluctuation in strip edges under different roll spacings, manufacturing cost and volume and other factors, a roll spacing of 100 mm is more reasonable. It is experimentally verified that when the roll gap is 0.4 mm and the roll spacing is 100 mm, the strip is successfully prepared in accordance with the cross-section requirements. When the rolling gap is 0.3 mm, due to stress\u2013strain concentration, the strip is prone to edge waves in forming. The top of corner 2 of the flange triangular region is susceptible to intermittent tear defects, and the crack extension mechanism is mainly based on the cleavage fracture + ductile fracture.<\/jats:p>","DOI":"10.3390\/ma16247608","type":"journal-article","created":{"date-parts":[[2023,12,12]],"date-time":"2023-12-12T05:23:22Z","timestamp":1702358602000},"page":"7608","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":4,"title":["Research on Cold Roll Forming Process of Strips for Truss Rods for Space Construction"],"prefix":"10.3390","volume":"16","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-5681-0892","authenticated-orcid":false,"given":"Xingwen","family":"Yang","sequence":"first","affiliation":[{"name":"School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China"},{"name":"Industrial Training Center, Zhongyuan University of Technology, Zhengzhou 451191, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jingtao","family":"Han","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China"},{"name":"Guangzhou Sino Precision Steel Tube Industry Research Institute Co., Ltd., Guangzhou 511300, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-1324-180X","authenticated-orcid":false,"given":"Ruilong","family":"Lu","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2023,12,12]]},"reference":[{"key":"ref_1","first-page":"3159","article-title":"Research Status and Prospect of On-orbit Additive Manufacturing Technology for Large Space Truss","volume":"35","author":"Yang","year":"2021","journal-title":"Mater. Rep."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"50","DOI":"10.1360\/N092018-00367","article-title":"The key mechanical problems of on-orbit construction","volume":"49","author":"Ding","year":"2019","journal-title":"Sci. Sin. -Phys. Mech. Astron."},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"1747","DOI":"10.1016\/j.asr.2011.01.014","article-title":"A deployable mast for solar sails in the range of 100\u20131000 m","volume":"48","author":"Brown","year":"2011","journal-title":"Adv. Space Res."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"107527","DOI":"10.1016\/j.ast.2022.107527","article-title":"Bi-level game-based reconfigurable control for on-orbit assembly","volume":"124","author":"Chai","year":"2022","journal-title":"Aerosp. Sci. Technol."},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"21","DOI":"10.1016\/j.cja.2020.09.043","article-title":"Review of in-space assembly technologies","volume":"34","author":"Xue","year":"2021","journal-title":"Chin. J. Aeronaut."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"881","DOI":"10.1016\/j.actaastro.2020.10.030","article-title":"Dynamics and on-orbit assembly strategies for an orb-shaped solar array","volume":"178","author":"Cao","year":"2021","journal-title":"Acta Astronaut."},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"112","DOI":"10.1177\/0266351117711290","article-title":"Deployable structures classification: A review","volume":"32","author":"Fenci","year":"2017","journal-title":"Inter. J. Space Stru."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"1645","DOI":"10.1016\/j.asr.2021.11.029","article-title":"Extrusion and thermal control design of an on-orbit 3D printing platform","volume":"69","author":"Tang","year":"2022","journal-title":"Adv. Space Res."},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"1","DOI":"10.1016\/j.actaastro.2017.11.005","article-title":"Sintering of micro-trusses created by extrusion-3D-printing of lunar regolith inks","volume":"143","author":"Taylor","year":"2018","journal-title":"Acta Astronaut."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"109575","DOI":"10.1016\/j.vacuum.2020.109575","article-title":"Feasibility study on feeding wire electron beam brazing of pure titanium using an electron gun for space welding","volume":"180","author":"Wang","year":"2020","journal-title":"Vacuum"},{"key":"ref_11","doi-asserted-by":"crossref","first-page":"320","DOI":"10.1080\/13621718.2018.1534794","article-title":"New electron beam gun for welding in space","volume":"24","author":"Paton","year":"2019","journal-title":"Sci. Technol. Weld. Join."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"1370","DOI":"10.1007\/s11663-020-01868-y","article-title":"Numerical Simulation and Parameter Design of Strip Cold Rolling Process of 301L Stainless Steel in 20-Roll Mill","volume":"51","author":"Li","year":"2020","journal-title":"Metall. Mater. Trans. B"},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"1082","DOI":"10.1007\/s00170-007-1066-0","article-title":"Dimensional errors of rollers in the stream of variation modeling in cold roll forming process of quadrate steel tube","volume":"37","author":"Zhang","year":"2008","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"108576","DOI":"10.1016\/j.tws.2021.108576","article-title":"Shape optimisation of cold roll formed sections considering effects of cold working","volume":"170","author":"Qadir","year":"2022","journal-title":"Thin-Walled Struct."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"1787","DOI":"10.1007\/s00170-018-2053-3","article-title":"Optimized bending angle distribution function of contour plate roll forming","volume":"97","author":"Su","year":"2018","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"219","DOI":"10.1016\/0924-0136(96)02333-3","article-title":"Longitudinal and shear strain development in cold roll forming","volume":"60","author":"Panton","year":"1996","journal-title":"J. Mater. Process. Technol."},{"key":"ref_17","first-page":"113","article-title":"Geometric Constraints on the Forming Path in Roll Forming Channel Sections","volume":"206","author":"Panton","year":"1992","journal-title":"J. Mater. Process. Technol."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"205","DOI":"10.1016\/S0924-0136(01)01041-X","article-title":"The effects of forming parameters in the roll-forming of a channel section with an outer edge","volume":"116","author":"Han","year":"2001","journal-title":"J. Mater. Process. Technol."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"531","DOI":"10.1007\/s12008-021-00818-5","article-title":"Experimental and mathematical analysis on spring-back and bowing defects in cold roll forming process","volume":"16","author":"Poursafar","year":"2022","journal-title":"Int. J. Interact. Des. Manuf. (IJIDeM)"},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"5803","DOI":"10.1007\/s00170-023-12004-w","article-title":"Influence of bending angle function on local thinning defects of roll-formed sheets based on segmental boundary combination optimization","volume":"127","author":"Su","year":"2023","journal-title":"Int. J. Adv. Manuf. Tech."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"1793","DOI":"10.1007\/s00170-020-05154-8","article-title":"A novel approach to springback control of high-strength steel in cold roll forming","volume":"107","author":"Cheng","year":"2020","journal-title":"Int. J. Adv. Manuf. Tech."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"4213","DOI":"10.1007\/s00170-021-08206-9","article-title":"A study of cold roll forming technology and peak strain behavior of asymmetric corrugated channels","volume":"118","author":"Xu","year":"2022","journal-title":"Int. J. Adv. Manuf. Tech."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"581","DOI":"10.1007\/s12289-016-1303-x","article-title":"Improvement strategy for edge waviness in roll bending process of corrugated sheet metals","volume":"10","author":"Shim","year":"2017","journal-title":"Int. J. Mater. Form."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"130","DOI":"10.1016\/j.tws.2015.03.002","article-title":"The effects of forming parameters on the cold roll forming of channel section","volume":"92","author":"Safdarian","year":"2015","journal-title":"Thin-Walled Struct."},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"181","DOI":"10.1007\/s00170-018-2885-x","article-title":"Effect of forming parameters on edge wrinkling in cold roll forming of wide profiles","volume":"101","author":"Najafabadi","year":"2019","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_26","doi-asserted-by":"crossref","unstructured":"Wang, J., Liu, H.M., Li, S.F., and Chen, W.J. (2022). Cold Roll Forming Process Design for Complex Stainless-Steel Section Based on COPRA and Orthogonal Experiment. Materials, 15.","DOI":"10.3390\/ma15228023"}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/24\/7608\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T21:37:10Z","timestamp":1760132230000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/24\/7608"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2023,12,12]]},"references-count":26,"journal-issue":{"issue":"24","published-online":{"date-parts":[[2023,12]]}},"alternative-id":["ma16247608"],"URL":"https:\/\/doi.org\/10.3390\/ma16247608","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2023,12,12]]}}}