Effects of manufacturing methods and production routes on residual stresses of rectangular and square hollow steel sections: a review

Rectangular and square hollow steel sections can be manufactured using either a “direct forming” or an “indirect forming” method. The production route for both “direct forming” and “indirect forming” techniques can be conducted at room temperature (cold forming) or elevated temperature (hot forming). It might also start by forming at room temperature and subsequently followed by heat treatment (hot-finishing). The manufacturing method and production route choice cause the final products that are roll-formed from the same material to possess different mechanical properties. One of the main reasons for the disparity of mechanical properties is the variation of residual stress induced during forming processes. In this paper, available numerical and experimental studies of different rectangular and square steel hollow sections manufacturing methods and production routes on residual stresses are comprehensively reviewed. Furthermore, studies on the effects of roll-forming parameters on product quality and residual stresses are integrated. Moreover, future research activities aiming to manufacture residual stresses-free rectangular and square hollow sections are recommended.