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Influence of the axial radius of rigid arc-shaped rollers in 3D surface rolling

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Abstract

The research and development of flexible forming technology have a crucial role in the personalized production and manufacturing of three-dimensional (3D) surface sheet metal parts. Three-dimensional surface rolling with rigid arc-shaped rollers (TSRRAR), a new flexible forming technology, was investigated to effortlessly produce 3D surface parts. Numerical simulation and experimental analysis mainly include data at four values of the difference in axial radius of roller (−2, 2, 6 and 10 mm) to explore this technology’s forming ability. It was demonstrated that various shapes could be obtained only based on one group of rollers. The maximum resultant force decreased from 3.07 to 2.21 KN, and the required maximum compression rate from 4.22 to 2.48 % with the same longitudinal curvature radius (179 mm) to be obtained. Therefore, the forming difficulty can be reduced by selecting the difference in axial radius of roller.

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Abbreviations

r :

Axial radius of roller

r d :

Difference in axial radii of the concave and convex rollers

\({L_{\widehat{AB}}}\) :

Length of circle arc AB

ε L (s):

Total longitudinal strain at point S

δ 0 :

Initial thickness of sheet

δ (s):

Thickness at point S

h (s):

Roll gap distribution function

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Author information

Authors and Affiliations

  1. Dieless Forming Technology Center of Roll Forging Research Institute, College of Materials Science and Engineering, Jilin University (Nanling Campus), Changchun, 130022, China

    Xintong Wang, Mingzhe Li, Yuwei Liu, Xiang Chang & Weifeng Yang

  2. Flight Research Institute, Aviation University of Air Force, Changchun, 130022, China

    Yuwei Liu

Authors
  1. Xintong Wang
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  2. Mingzhe Li
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  3. Yuwei Liu
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  4. Xiang Chang
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  5. Weifeng Yang
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Corresponding author

Correspondence to Mingzhe Li.

Additional information

Xintong Wang is a Ph.D. student in the College of Materials Science and Engineering at Jilin University. He received his B.S. from Roll Forging Research Institute at Jilin University. His research field is flexible plastic forming of sheet metal.

Mingzhe Li is currently a Professor in the College of Materials Science and Engineering at Jilin University. He received his B.S. and M.S. degrees from Jilin University of Technology, Changchun, China in 1977 and 1981, respectively. He then obtained his Ph.D. degree from Nagaoka University of Technology, Japan in 1990. Prof. Li’s primary research interests include flexible plastic forming and digital manufacturing of sheet metal.

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Wang, X., Li, M., Liu, Y. et al. Influence of the axial radius of rigid arc-shaped rollers in 3D surface rolling. J Mech Sci Technol 35, 3579–3589 (2021). https://doi.org/10.1007/s12206-021-0729-3

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  • DOI: https://doi.org/10.1007/s12206-021-0729-3

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