Study on forming sequences of the auxiliary roll height in flexible asymmetric rolling process

  • 18 Accesses


Flexible asymmetric rolling process has been conceived to manufacture sheet metal parts with high efficiency. In the asymmetric rolling process, the metal plate is fed into the roll gap at a tilted angle. The nip angles of the top and bottom rolls are not equal, and inconsistent thickness thinning occurs on the two surfaces of the metal plate. It is easy to bend the metal plate during the asymmetric rolling process. Then, desired metal parts with three-dimensional deformation are generated though non-uniformly rolling in the thickness direction. Compared with the 3D rolling technology, shape precision of the metal part with desired configuration is significantly improved. In this paper, the forming sequences of the auxiliary roll height are investigated for forming surface parts. A series of auxiliary roll heights are selected for the metal plate in condition of same roll gap distribution. Numerical simulations and experiments for typically surface parts have been performed. Deformation degree and shape accuracy of the surfaces parts formed in different auxiliary roll heights have been respectively compared and analyzed. Through analyzing deformation degree and shape accuracy of the surfaces parts, it is beneficial for parameters optimization of the flexible asymmetric rolling process.

This is a preview of subscription content, log in to check access.

Access options

Buy single article

Instant unlimited access to the full article PDF.

US$ 39.95

Price includes VAT for USA

Subscribe to journal

Immediate online access to all issues from 2019. Subscription will auto renew annually.

US$ 199

This is the net price. Taxes to be calculated in checkout.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11


  1. 1.

    Dakhli M, Boulila A, Tourki Z (2017) Effect of generatrix profile on single-point incremental forming parameters. Int J Adv Manuf Technol 93:2505–2516

  2. 2.

    Cai ZY, Sui Z, Cai FX, Liu L (2013) Continuous flexible roll forming for three-dimensional surface part and the forming process control. Int J Adv Manuf Technol 66:393–400

  3. 3.

    Yamashita I, Yamakawa T (1988) Apparatus for forming plate with a double-curved surface United States 4770017

  4. 4.

    Yoon SJ, Yang DY (2003) Development of a highly flexible incremental roll forming process for the manufacture of a doubly curved sheet metal. CIRP Ann Manuf Technol 52(1):201–204

  5. 5.

    Shim DS, Yang DY, Kim KH, Han MS, Chung SW (2009) 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 Ann Manuf Technol 58(1):239–242

  6. 6.

    Shim DS, Yang DY, Kim KH, Chung SW, Han MS (2010) Investigation into forming sequences for the incremental forming of doubly curved plates using the line array roll set (LARS) process. Int J Mach Tools Manuf 50:214–218

  7. 7.

    Hu ZQ, Li MZ, Cai ZY, Gong XP (2009) Continuous flexible forming of three-dimensional surface parts using bending rollers. Mat Sci Eng A-Struct 499:234–237

  8. 8.

    Cai ZY, Li MZ, Lan YW (2012) Three-dimensional sheet metal continuous forming process based on flexible roll bending: principle and experiments. J Mater Process Technol 212:120–127

  9. 9.

    Cai ZY, Li MZ (2013) Principle and theoretical analysis of continuous roll forming for three-dimensional surface parts. Sci China Tech Sci 2:351–358

  10. 10.

    Wang DM, Li MZ, Cai ZY (2014) Continuous-forming method for three-dimensional surface parts combining rolling process with multipoint-forming technology. Int J Adv Manuf Technol 72:201–207

  11. 11.

    Wang M, Cai ZY, Li LL, Li MZ (2015) Longitudinal bending deformation analysis of sheet metal in continuous roll forming process. Int J Adv Manuf Technol 80(1–4):467–476

  12. 12.

    Wang M, Lu GL, Cai ZY, Li MZ (2018) Research on continuous roll forming for manufacturing 3D curved surface parts with variable transverse curvatures. J Manuf Process 36:459–464

  13. 13.

    Liu K, Fu WZ, Li MZ, Li Y, Yi Z (2019) Research on flexible rolling process of three-dimensional surface part using auxiliary rolls. Int J Adv Manuf Technol 103:1433–1442

  14. 14.

    Wang DM, Yu CA, Li MZ, He XZ, Xie ZJ, Wang L (2018) Research on flexible asymmetric rolling process for three-dimensional surface parts. Int J Adv Manuf Technol 95:2339–2347

Download references

Author information

Correspondence to Daming Wang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Wang, D., Yu, C., Meng, L. et al. Study on forming sequences of the auxiliary roll height in flexible asymmetric rolling process. Int J Adv Manuf Technol 106, 1375–1384 (2020) doi:10.1007/s00170-019-04731-w

Download citation


  • Curved surface part
  • Asymmetric rolling
  • Flexible rolling
  • Shape accuracy
  • Finite element analysis