Principle and theoretical analysis of continuous roll forming for three-dimensional surface parts
Principle and theoretical analysis of continuous roll forming for three-dimensional surface parts
复制标题
三维曲面零件连续滚压成形原理与理论分析
DOI：
10.1007/s11431-012-5081-5
复制
发表时间：
2013-02-01
影响因子：
4.6
通讯作者：
Li MingZhe
中科院分区：
文献类型：
--
作者：
Cai ZhongYi;Li MingZhe
连续辊弯成形（CRF）是一种新型的三维曲面零件成形工艺，它采用一对可弯曲的成形辊作为成形工具。通过控制上下成形辊之间的差距，在轧制过程中，金属板在纵向上不均匀地延伸，而在横向上弯曲。其结果是，纵向弯曲获得和双曲面形成。随着成形辊的旋转，金属板连续变形，并且三维表面部分连续成形。本文阐述了CRF中三维表面形成的机理。通过对CRF工艺的理论分析，建立了轧制过程中弯曲变形的控制方程。在对变形和材料模型进行简化的基础上，推导了纵弯变形的计算公式，给出了轧制压缩比和辊缝的设计方法，分析了轧制压缩比和板料宽度对纵弯曲率的影响。典型曲面零件的成形试验和实测结果表明，CRF工艺可获得精度良好的成形结果。
Continuous roll forming (CRF) is a novel forming process for three-dimensional surface parts, in which a pair of bendable forming rolls is used as sheet metal forming tool. By controlling the gap between the upper and lower forming rolls, sheet metal is non-uniformly extended in the longitudinal direction while it is bent in the transverse direction during the rolling process. As a result, longitudinal bending is gained and a doubly curved surface is formed. With the rotations of the forming rolls, the sheet metal is deformed consecutively, and a three-dimensional surface part is shaped continuously. In this paper, the mechanism of the three-dimensional surface formation in CRF is set forth. Through theoretical analysis of the CRF process, the governing equations for the bending deformation in rolling process are presented. Based on the simplification on the deformation and material model, the formulation to calculate the longitudinal bending deformation is derived, and the methods to design the compression ratio and the roll gap are given, the effects of compression ratio of rolling and the width of blank sheet on the longitudinal bending curvature are analyzed. The forming experiments on typical surface parts and measured results show that forming results with good precision can be obtained by CRF process.