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Shape error prediction and compensation of three-dimensional surface in flexibly-reconfigurable roll forming

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Abstract

The Flexibly-reconfigurable roll forming (FRRF) scheme as one of the advanced continuous roll forming processes consists of upper and lower flexible rollers that can be controlled by each reconfigurable punch module. The shape error in the FRRF process often results in undesirable changes in the shape of the deformed surface and brings about a deviation in the precision of the deformed product. This study considers the changes in the shape error of a deformed configuration by controlling the non-uniform gap between both flexible rollers in the transverse direction. A Non-uniform rational B-spline (NURBS) type control methodology is introduced based on the transverse target curve and the thickness reduction ratio. The function for the transverse target curve is reconstructed by using a NURBS curve, and the function of the reduction ratios of the thickness is assumed to have linear increments. Finite element simulations are conducted for the FRRF process with the AA5052-H32 sheet material by applying NURBS-type control methodology for both flexible rollers. The transverse shape error of the three-dimensional surface is predicted by using a numerical approach, and its results are experimentally verified. A Reverse displacement compensation (RDC) method is adopted to compensate the transverse shape error of the deformed surface. Consequently, the proposed RDC method is validated as a suitable approach to address the transverse shape error. This method contributes to further developing capabilities to modify the profiles of the upper and lower flexible rollers in the flexibly-reconfigurable roll forming process for various 3D surface parts.

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Authors and Affiliations

  1. Department of Aerospace Engineering, Pusan National University, Busan, 609-735, Korea

    Pan Liu & Beom-Soo Kang

  2. Engineering Research Center of Innovative Technology on Advanced Forming, Pusan National University, Busan, 609-735, Korea

    Tae-Wan Ku

Authors
  1. Pan Liu
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  2. Tae-Wan Ku
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  3. Beom-Soo Kang
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Corresponding author

Correspondence to Beom-Soo Kang.

Additional information

Recommended by Associate Editor Dae-Cheol Ko

Pan Liu received his B.S. degree in Material Processing Engineering from Henan University of Science and Technology in 2004, and his M.S. degree in Material Processing Engineering from Chongqing University, China, in 2011. At present, he is a Ph.D. candidate of Aerospace Engineering at Pusan National University, Korea. His research interests include flexibly- reconfigurable roll forming process and multi-point dieless forming technology.

Tae-Wan Ku received his B.S., M.S. and Ph.D. degrees in Aerospace Engineering from Pusan National University, S. Korea, in 1997, 1999 and 2003, respectively. Dr. Ku is currently a professor at the ERC/ITAF (engineering research center of innovative technology on advanced forming) at Pusan National University in Busan, S. Korea. His research interests include flexibly-reconfigurable roll forming technology, tube Ubending process for steam generator, process modification of cold forging, multi-stage deep drawing and forming limit surface theory.

Beom-Soo Kang received his B.S. degree in Mechanical Engineering from Pusan National University in 1981, and his M.S. degree in Aerospace Engineering from KAIST in 1983, S. Korea. He then obtained his Ph.D. degree from the University of California at Berkeley, USA, in 1990. Dr. Kang is currently a Professor at the Department of Aerospace Engineering at Pusan National University in Busan, S. Korea. His research interests include materials processing, FEM, and flexiblyreconfigurable roll forming technology.

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Liu, P., Ku, TW. & Kang, BS. Shape error prediction and compensation of three-dimensional surface in flexibly-reconfigurable roll forming. J Mech Sci Technol 29, 4387–4397 (2015). https://doi.org/10.1007/s12206-015-0937-9

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  • DOI: https://doi.org/10.1007/s12206-015-0937-9

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