Engineering Design Conference

Shape Corp.’s Roll Form Shaft Deflection senior project focused on improving the way shaft deflection was tested, modeled, and predicted in roll forming equipment. Roll forming is an important manufacturing process used to create consistent automotive components, but shaft deflection could affect alignment, process stability, tooling performance, and final part quality. The project shifted toward gaining a more accurate understanding of how the shaft behaved under load and using that information to support future design decisions. The team used an experimental setup with external measurement methods to collect more reliable physical test data. These results were then compared with the FEA model to verify its accuracy and improve confidence in the simulation. If differences were found, the model could be refined by reviewing assumptions such as loading, supports, constraints, and material behavior. Once verified, the FEA model was used to study different shaft and tooling conditions without requiring excessive physical testing. The final goal was to compile the validated results into a user-friendly predictive model that could help Shape Corp. estimate shaft deflection and support shaft sizing decisions for future roll forming applications and improve engineering confidence during early project planning and setup.