Analysis of Flexible Roller Parameters Influences on Roll Forming of Three-Dimensional Parts

Abstract:

Roll forming is a well known bending process and sheet metals can only be machined into two-dimensional surfaces in traditional roll forming. While with more and more personalized demands, three-dimensional surfaces are widely required. Thus, flexible rollers are used to achieve three-dimensional surfaces. And in order to optimize experimental parameters and to predict experimental results, finite element method (FEM) is developed. In this paper the set-up of flexible roll-forming is described and the process of roll forming is simulated. Then the influences of forming parameters, such as the thickness and the roll velocity, on forming quality of the sheet metal in roll forming process are discussed. The results show that the analysis of flexible roller parameters is practical for the continuous and efficient forming of three-dimensional surfaces.

• Periodical: Advanced Materials Research (Volumes 875-877)
• Pages: 450-454
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.875-877.450
• Online since: February 2014
• Authors: Jiao Jiao Zhen, Zhi Qing Hu, Zeng Ming Feng, Jun Hui Cao
• Keywords: Finite Element Method (FEM), Flexible Roll, Roll Forming, Sheet Metal, Three-Dimensional Surface

References

[1] Kozo Osakada*. History of Plasticity and Metal Forming Analysis[J]. Journal of Materials Processing Technology 210 (2010) 1436–1454.

DOI: 10.1016/j.jmatprotec.2010.04.001

[2] E. Trostmann, N.E. Hansen. General Scheme for Automatic Control of Bending of Beams[J]. Transactions of the ASME, June, 1982, 104: 173.

[3] S. J Hemmat, J.G. Shin. Estimation of flame parameters for flame bending process[J]. International Journal of Machine Tools& Manufacture, 2007. 47: 799-804.

DOI: 10.1016/j.ijmachtools.2006.09.005

[4] T. Wang, M.J. Platts, A. Levers. A process model for shot peen forming[J]. Journal of Processing Technology, 2006. 172: 159-162.

DOI: 10.1016/j.jmatprotec.2005.09.006

[5] Zhiqing Hu, Zingzhe Li, Xuepeng Gong, Zengming Feng. Forming 3D Sheet Metals by Means of Continuous Rolling Method. Applied Mechanics and Materials. 2009. 16-19：570~574.

DOI: 10.4028/www.scientific.net/amm.16-19.570

[6] Zhiqing Hu，Mingzhe Li, Zhongyi Cai, Xuepeng Gong. Continuous flexible forming of three-dimensional surface parts using bendable rollers. Materials science and engineering. 2009. 499: 234-237.

DOI: 10.1016/j.msea.2007.11.107

[7] Zhiqing Hu, Ji Zhao, Yushan Deng, Haohan Zhang. Numeral Simulation of a New Forming Process: Stretch Forming Combined with Roll Forming. Advanced Materials Research. 2011. 189-193: 2399-2403.

DOI: 10.4028/www.scientific.net/amr.189-193.2399

[8] Shanxi Province Chemical Industry Research Institute. Polyurethane elastomer manual [M]. Chemical industry press. 2001. In Chinese.

[9] Mingyuan Fu, Hanjing Sun. Polyurethane Elastomer and Its Application[M]. Chemical industry press. 2006. In Chinese.

[10] Weimin Jia, Zhengang Feng. The Study of High Hardness Polyurethane Elastomer [A]. Shanxi, Shanxi Province chemical industry research institute. 2005. in Chinese.

[11] G. Li, J. T. Jinn, W.T. Wu, S. I. Oh. Recent Development and Applications of Three-dimensional Finite Element Modeling in Bulk Forming Process[J]. Journal of Materials Processing Technology. 113 (2001) 40- 45.

DOI: 10.1016/s0924-0136(01)00590-8

[12] Fuxiao Chen, Yanmin Zhang, The Application of Finite Element in the Plastic Forming[M]. Beijing. Chemical industry press. 2010. In Chinese.

[13] Tonglin Li, Suiyu Yin, Elastic-plastic Mechanics[M]. China university of geosciences press. 2006. In Chinese.