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In order to avoid the defects of bending angle thinning and fillet sharpening in cold bending process of sporting channel steel, improve the joint stiffness, ultimate bearing capacity and mechanical properties of components, the design and optimization of the number of forming passes and the bending angle increment were researched. Then, considering the parameters such as blank thickness, bending angle and bending radius, the actual material width was calculated, and the forming sequence was determined. Furthermore, the total number of passes was calculated according to the empirical formula for the number of forming passes, and the bending angle increment between each pass was calculated by the bending angle distribution formula. In addition, the finite element simulation analysis was conducted by Hauschild model, the bending angle increment between each pass was adjusted by the simulate results to determine the optimal pass number and the bending angle increment. Finally, the validity of the optimization results was verified in combination with the production equipment. The results show that the unreasonable strain exceeding the limit value during the cold bending process is analyzed based on the simulation results of software COPRA, and the maximum strain value in the cold bending process is reduced by changing the number of forming passes and the bending angle increment, which can effectively reduce the defects of bending angle thinning and fillet sharpening.
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