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Received Apr 17, 2017; Revised Jun 19, 2017; Accepted Jul 11, 2017
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1. Introduction
Cold roll-beating technology is a new type of chipless near-net forming technology that enables environmental protection and energy savings with high efficiency, a high material utilization rate, and an extensive application value in the automobile industry and the aerospace sector and for major strategic equipment manufacturing processes. High-speed cold roll forming is a progressive forming process during nonuniform thermal mechanical coupling. The forming process of a workpiece surface will inevitably produce residual stress. Residual stress can reduce the surface microcrack expansion of a workpiece and increase its fatigue strength, which will affect the stability of the workpiece size [1–5]. Residual stress is an important parameter for the surface performance of a workpiece, and its type and peak size and depth of the working layer are important factors that affect the surface properties of cold-rolled workpieces. However, various questions arise during the actual production process. How do different cold roll-beating process parameters affect the workpiece residual stress state and its distribution? What method can be employed to predict the surface residual stress of a cold roll-beating workpiece when setting the cold rolling process parameters? What method can be employed to optimize the cold roll-beating process parameters according to the stress state of the workpiece application? Research on the spatial distribution and prediction model of the residual stresses in cold roll-beating during nonuniform thermal mechanical coupling is necessary. Providing accurate control of residual stress during cold roll-beating and optimization of the cold roll-beating processing parameters improve the surface performance of cold roll-beating workpiece forming and have theoretical...