Analysis of continuous roll forming for manufacturing 3D surface part with lateral bending deformation
Analysis of continuous roll forming for manufacturing 3D surface part with lateral bending deformation
复制标题
制造具有横向弯曲变形的 3D 曲面零件的连续滚压成型分析
DOI：
10.1007/s00170-017-0510-z
复制
发表时间：
2017-11-01
影响因子：
3.4
通讯作者：
Cai, Zhong-Yi
中科院分区：
文献类型：
--
作者：
Wang, Mi;Liu, Zhen-ning;Cai, Zhong-Yi
连续滚压成型 (CRF) 是一项用于单件和小批量制造 3D 表面钣金零件的新技术。在CRF工艺中，放置一对柔性辊以形成不均匀的辊缝。当柔性辊以相同角速度沿相反方向旋转时，金属板料在摩擦力的作用下咬入辊缝，金属板料在厚度方向上不均匀减薄，在纵向上被拉长。因此，连续地制造出具有期望形状的3D表面部件。本文将CRF进一步发展并扩展为LB-CRF，使得CRF工艺不仅能够制造具有横向和纵向弯曲变形的3D曲面零件，而且还能够制造具有横向弯曲变形的3D曲面零件（LB-CRF）。给出了柔性辊曲面轮廓和辊缝分布的设计方法。通过对LB-CRF过程的一系列数值模拟，验证了所提出的设计方法。讨论了辊缝分布与横向弯曲曲率半径的关系。通过实验提出了LB-CRF工艺，结果验证了采用LB-CRF工艺制造横向弯曲3D曲面零件的可行性。
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.