Abstract
Flexibly reconfigurable roll forming (FRRF) is a sheet-forming technology that can be used to produce multi-curvature surfaces by controlling the longitudinal strain distribution. In FRRF, the shape of the formed surface is determined by the curvature of the reconfigurable rollers and the gaps between the rollers. Because FRRF technology is still under development, a simulation model of the physical forming process is conveniently used to investigate the effects of the input parameters. To facilitate the investigation in the present study, the response surface methodology is used to develop a model for predicting the curvature produced in a longitudinal blank. The input parameters are the sheet compression ratio, the curvature radius in the transverse direction, and the initial blank width. Samples are generated using a three-level three-factor full-factorial design, and each convex and saddle curvature is represented by a quadratic regression model with two-factor interactions. The fitted polynomial equations are verified numerically by the R-squared values and root mean square errors and graphically by residual plots. To assess the reliability of the sample data, experiments are performed using pre-FRRF equipment. The proposed analytical procedure is confirmed to be reasonable, and a statistical formula for estimating the longitudinal curvature produced by the FRRF process is established.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Heo SC, Seo YH, Song WJ, Kim J, Kang BS, Ku TW (2008) Numerical and experimental investigation on product configuration using flexible forming process. Steel Res Int 79(1):640–647
Quan GZ, Ku TW, Kang BS (2011) Improvement of formability for multi-point bending process of AZ31B sheet material using elastic cushion. J Precis Eng Manuf 12(6):1023–1030
Wang D, Li MZ, Cai ZY (2014) Investigation on forming precision of flexible rolling process for three-dimensional surface parts of different sheet materials. Procedia Eng 81:227–232
Yoon JS, Son SE, Song WJ, Kim J, Kang BS (2014) Study on flexibly-reconfigurable roll forming process for multi-curved surface of sheet metal. Int J Precis Eng Manuf 15(6):1069–1074
Myers RH, Montgomery DC, Anderson-cook CM (2009) Response surface methodology—process and product optimization using designed experiments, 3rd edn. Wiley, New Jersey, pp 13–62
Ganjigatti JP, Pratihar DK, Roy Choudhury A (2007) Global versus cluster-wise regression analyses for prediction of bead geometry in MIG welding process. J Mater Process Technol 189:352–366
Çaydaş U, Hasçalık A (2008) A study on surface roughness in abrasive waterjet machining process using artificial neural networks and regression analysis method. J Mater Process Technol 202:574–582
Kamal Bashah NA, Muhamad N, Deros BM, Zakaria A, Ashari S, Mobin A, Mohd Abdul Lazat MS (2013) Multi-regression modelling for springback effect on automotive body in white stamped parts. Mater Des 46:175–190
Seo YH, Kang BS, Kim J (2012) Study on relationship between design parameters and formability in flexible stretch forming process. Int J Precis Eng Manuf 13(10):1797–1804
Kang BS, Yoon JS (2013) Sheet forming apparatus with flexible rollers. PCT patent (PCT2013134KR)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Park, JW., Yoon, J., Lee, K. et al. Rapid prediction of longitudinal curvature obtained by flexibly reconfigurable roll forming using response surface methodology. Int J Adv Manuf Technol 91, 3371–3384 (2017). https://doi.org/10.1007/s00170-017-9999-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-9999-4