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Project Number: YR-CH05 Optimize Stress in Roll Forming A Major Qualifying Project Report Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in partial fulfillment of the requirements for the Degree of Bachelor of Science in Mechanical Engineering By Richard Jorgenson W. Jake Doucet From HUST: Chen Chen Bai Hua Date: 8-31-2006 Approved: Prof. Yiming Rong, Major Advisor Keywords 1. Roll forming 2. Metallography 3. Grain distortion Prof. Yuan, Co-AdvisorAcknowledgments We would like to thank everyone involved for this wonderful opportunity and any help given along the way. First and foremost, thanks to Professor Rong for organizing and advising the project. Thanks to CISs CEO Al Barry and GM Chay Chin Tat for providing the opportunity to work with CIS in China. To the engineers that worked with the group Dennis Koh, Yang Wenming, and Xiao Jun for support and guidance. To Karen Xu for overseeing all of the logistics of the groups stay at CIS. Thanks to Lab Manager Zhou Lifen for use of lab equipment at CIS. To everyone else at CIS who helped us in any capacity. To all of the members of HUST during the project who helped make our stay in China so much more enjoyable. Thanks to Professor Yuan and Graduate Student Qi Peng of HUST for insight and guidance during the project. Lastly and certainly not least to our Chinese Partners at HUST Bai Hua and Chen Chen, who were excellent hosts and workers. Abstract In an effort to supply tooling designers with more accurate data the effects of tooling design on final product variation were investigated. Redundant Deformations were citied as the main source of variation in tooling design. Experiments were carried out to investigate and add to the body of knowledge of this claim.Table of ContentsAcknowledgments 2 Abstract 3 1 Table of Contents 4 2 Introd