Abstract
Continuous roll forming (CRF) is a process to form three-dimensional surface based on the rolling deformation of sheet metal. Unlike traditional rolling process where the working rolls are straight and rigid, two small-diameter bendable forming rolls are used herein, and the sheet metal is bent in longitudinal and transverse directions simultaneously after it is compressed between a pair of bended rolls. The formed surface is controlled by the curved shapes of the forming rolls and the gap between the two rolls, and the roll gap is the crucial parameter of CRF process. In this paper, the required velocity distribution of material across the exit of roll gap for the formation of a smooth surface is analyzed, the formulations for the CRF process design is derived and a method to predict the longitudinal bending deformation generated by roll gap is presented. Finally, the validity of the presented methods and theoretical models are demonstrated by numerical simulations and CRF tests for typical surface parts.
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Cai, ZY., Li, LL., Wang, M. et al. Process design and longitudinal deformation prediction in continuous sheet metal roll forming for three-dimensional surface. Int. J. Precis. Eng. Manuf. 15, 1889–1895 (2014). https://doi.org/10.1007/s12541-014-0543-2
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DOI: https://doi.org/10.1007/s12541-014-0543-2