Monday 08 February 2021

Innovative research by Kersten engineer Roy Cornelissen featured on

For his graduation project of the Structural Engineering master's program at the Technical University Eindhoven, Roy Cornelissen, R&D Engineer at Kersten, researched wrinkling and buckling of the compressed plate part at the inner radius of aluminium hollow sections during the three-point-roll bending process.
His research has revealed new theories and interesting insights. Even so innovative in fact, that the research study was published in The International Journal of Advanced Manufacturing Technology.


Scientific study into buckling and wrinkling of aluminium hollow sections with three-point-roll bending.

Cornelissen started his research by asking the craftsmen at Kersten about their practical findings regarding buckling and wrinkling during the rolling process of aluminum hollow sections. When does undesired deformation occur and what do they think it is caused by?

He then conducted a literature study and inventoried what research and publications were already available. It turned out that wrinkling has already been extensively studied for the rotary-draw bending process, but only one publication could be found on three-point-roll bending. However, in this case no mandrel was applied to support the inside of the profile, which is applicable to Cornelissen's research.

Cornelissen selected the most important parts of the existing studies and then filled in the gaps for the case considered and missing data with his own theories, analyses and calculations.

Groundbreaking results
In his publication, Cornelissen presents an analytical model to predict the conditions under which undesirable deformation of an aluminum hollow section can occur.
Groundbreaking in this research was the equation in which the stability of the plate part is supported by a theoretically infinite cross section. Based on this, a critical bending radius can be found depending on the sheet slimness. The finite element model was validated with an experiment. Both confirm that no undesired deformation occurs when the applied radius is larger than the critical radius predicted by the model.

Scientific publication
Cornelissen's research report reveals new theories and insights and is supported by Professor Johan Maljaars and Hèrm Hofmeyer. The results are so innovative that the report has been published by Springer, international publisher of scientific journals and books.

The full publication is included in The International Journal of Advanced Manufacturing Technology 112, 2091-2107 (2021) and available as download via the website of

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