Advertisement

Analysis of continuous roll forming for manufacturing 3D surface part with lateral bending deformation

  • Mi Wang
  • Zhen-ning Liu
  • Guo-Long Lu
  • Zhong-Yi Cai
ORIGINAL ARTICLE

Abstract

Continuous roll forming (CRF) is a novel technology for both single-piece and small-batch manufacturing of 3D surface sheet metal parts. In the CRF process, a pair of flexible rolls is placed to form a non-uniform roll gap. When the flexible rolls rotate in opposite directions with identical angular velocity, the sheet metal is bitten into the roll gap by frictional force, and the sheet metal is non-uniformly thinned in thickness direction and elongated in longitudinal direction. Thus, a 3D surface part with a desired shape is manufactured consecutively. In this paper, CRF is further developed and expanded into LB-CRF, which enables the CRF process to manufacture 3D surface parts not only with transverse and longitudinal bending deformation but also with lateral bending deformation (LB-CRF). The methods to design the curved profiles of flexible rolls and the distribution of the roll gap are provided. Through a series of numerical simulations on the LB-CRF processes, the proposed design methods are verified. The relationship between the distribution of the roll gap and radius of lateral bending curvature is discussed. The LB-CRF processes were presented through experiments, and the results validate the feasibility of adopting the LB-CRF process to manufacture 3D surface part with lateral bending.

Keywords

Continuous forming Flexible roll 3D surface part Numerical simulation Lateral bending 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.

References

  1. 1.
    Yoon SJ, Yang DY (2005) An incremental roll forming process for manufacturing doubly curved sheets from general quadrilateral sheet blanks with enhanced process features. CIRP Ann Manuf Technol 54:221–224CrossRefGoogle Scholar
  2. 2.
    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 52:201–204CrossRefGoogle Scholar
  3. 3.
    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. International Journal of Machine Tools & Manufacture 50:214–218CrossRefGoogle Scholar
  4. 4.
    Shim DS, Yang DY (2014) Multi-stage forming using optimized preform in the line array roll set process and its industrial application. International Journal of Precision Engineering & Manufacturing. 15:2085–2092CrossRefGoogle Scholar
  5. 5.
    Hu ZQ, Li MZ, Cai ZY, Gong XP (2009) Continuous flexible forming of three-dimensional surface parts using bendable rollers. Materials Science & Engineering A 499:234–237CrossRefGoogle Scholar
  6. 6.
    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 212:120–127CrossRefGoogle Scholar
  7. 7.
    Cai ZY, Sui Z, Cai FX, Liu L (2012) Continuous flexible roll forming for three-dimensional surface part and the forming process control. Int J Adv Manuf Technol 66:393–400CrossRefGoogle Scholar
  8. 8.
    Sui Z, Cai Z, Lan Y, Liu L (2014) Simulation and software design of continuous flexible roll bending process for three dimensional surface parts. Mater Des 54:498–506CrossRefGoogle Scholar
  9. 9.
    Cai ZY, Wang M, Li MZ (2014) Study on the continuous roll forming process of swept surface sheet metal part. J Mater Process Technol 214:1820–1827CrossRefGoogle Scholar
  10. 10.
    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 80:467–476CrossRefGoogle Scholar
  11. 11.
    Cai ZY, Li LL, Wang M, Li MZ (2014) Process design and longitudinal deformation prediction in continuous sheet metal roll forming for three-dimensional surface. International Journal of Precision Engineering & Manufacturing 15:1889–1895CrossRefGoogle Scholar
  12. 12.
    Wang D, Li M, Wang Y, Cai Z, Liu H (2015) Investigation and improvement of 3D rolling process for 3D surface parts. Int J Adv Manuf Technol 78:407–417CrossRefGoogle Scholar
  13. 13.
    Wang D, Li M, Cai Z (2014) Continuous-forming method for three-dimensional surface parts combining rolling process with multipoint-forming technology. Int J Adv Manuf Technol 72:201–207CrossRefGoogle Scholar
  14. 14.
    Fischer FD, Rammerstorfer FG, Friedl N (2003) Residual stress-induced center wave buckling of rolled strip metal. J Appl Mech 70:84–90CrossRefMATHGoogle Scholar
  15. 15.
    Mingzhe LI (2012) Continuous forming method for three-dimensional surface parts based on the rolling process using bended roll. Journal of Mechanical Engineering 48:44–49Google Scholar
  16. 16.
    Li HW, Ren GY, Li ZJ, Feng L, Yang H (2016) Forming mechanism and characteristics of a process for equal-thickness in-plane ring roll-bending of a metal strip by twin conical rolls. J Mater Process Technol 227:288–307CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  • Mi Wang
    • 1
    • 2
  • Zhen-ning Liu
    • 1
  • Guo-Long Lu
    • 1
  • Zhong-Yi Cai
    • 3
  1. 1.Key Laboratory for Bionic Engineering (Ministry of Education)Jilin University (Nanling Campus)ChangchunPeople’s Republic of China
  2. 2.School of EngineeringChangchun Normal UniversityChangchunPeople’s Republic of China
  3. 3.Roll Forging Research InstituteJilin University (Nanling Campus)ChangchunPeople’s Republic of China

Personalised recommendations