Mechanical mechanism of continuous roll forming for three-dimensional surface parts and the calculation of bending deformation

被引：6

作者：

机构：

[1] Roll Forging Research Institute, Jilin University

来源：

Cai, Z. (caizy@jlu.edu.cn) | 1600年 / Chinese Mechanical Engineering Society卷 / 49期

关键词：

Bended roll; Continuous forming; Curved surface; Rolling; Sheet metal;

D O I：

10.3901/JME.2013.02.035

中图分类号：

学科分类号：

摘要：

Continuous roll forming(CRF) is a new forming method for sheet metal, the three-dimensional surface part can be formed by using two bended forming rolls. The mechanical analysis on the deformation process from sheet blank to the curved surface in CRF is carried out, the deformation and material models are simplified, according to the equilibrium of internal force in the formed surface, the basic equations for governing bending deformation in longitudinal direction(rolling direction of forming rolls) are set forth, the formulations for calculating the radius of bending curvature in longitudinal direction based on the rolling strain are presented, and the method to design the gap between the upper and lower rolls is given. Analysis results show that, when the initial rolling strain is linearly distributed in the height direction, there are no residual stresses in the final formed surface, in addition, the bending curvature in longitudinal direction is determined by the maximum height difference and the compression ratio difference in the cross-section. Through the analyses on the process of CRF, the condition to realize the continuous roll forming for curved surface is achieved and the effects of the compression ratio difference and the geometrical parameters of the curved surface on the bending deformation in longitudinal direction are obtained. Experimental examples of CRF verify the effectiveness and practicability of the proposed theory and formulations. © 2013 Journal of Mechanical Engineering.

引用

页码：35 / 41

页数：6

共 13 条

[1] Yoon S.J., Yang D.Y., Development of a highly flexible incremental roll forming process for the manufacture of a doubly curved sheet metal, CIRP Annals-Manufacturing Technology, 52, 1, pp. 201-204, (2003)
[2] Yoon S.J., Yang D.Y., An incremental roll forming process for manufacturing doubly curved sheets from general quadrilateral sheet blanks with enhanced process features, CIRP Annals-Manufacturing Technology, 54, 1, pp. 221-224, (2005)
[3] Shim D.S., Yang D.Y., Kim K.H., Et al., Numerical and experimental investigation into cold incremental rolling of doubly curved plates for process design of a new LARS (line array roll set) rolling process, CIRP Annals-Manufacturing Technology, 58, 1, pp. 239-242, (2009)
[4] Shim D.S., Yang D.Y., Kim K.H., Et al., Investigation into forming sequences for the incremental forming of doubly curved plates using the line array roll set (LARS) process, International Journal of Machine Tools & Manufacture, 50, pp. 214-218, (2010)
[5] Li M., Hu Z., Cai Z., Et al., method of multipoint continuous forming for the freeform surface parts, Chinese Journal of Mechanical Engineering, 43, 12, pp. 155-159, (2007)
[6] Cai Z., Li M., Hu Z., Et al., Theoretical analysis and springback control of continuous flexible forming technology for three-dimensional surface parts, Chinese High Technology Letter, 21, 6, pp. 607-611, (2011)
[7] Cai Z., Li M., Lan Y., Three-dimensional sheet metal continuous forming process based on flexible roll bending: Principle and experiments, Journal of Materials Processing Technology, 212, 1, pp. 120-127, (2012)
[8] Zeng J., Liu Z., Champliaud H., FEM dynamic simulation and analysis of the roll-bending process for forming a conical tube, Journal of Materials Processing Technology, 198, 1-3, pp. 330-343, (2008)
[9] Lin Y.H., Hua M., Influence of strain hardening on continuous plate roll-bending process, International Journal of Non-Linear Mechanics, 35, 5, pp. 883-896, (2000)
[10] Wang P., Zhang D., Liu J., Et al., Research and application of the flatness measurement calculation model on cold rolling mill, Journal of Mechanical Engineering, 47, 4, pp. 58-65, (2011)

← 1 2 →