Device design and forming process analysis of curved rigid roll rolling process for three-dimensional surface

2021 ◽  
Vol 113 (9-10) ◽  
pp. 2481-2493
Author(s):  
Heng-yi Yuan ◽  
Yi Li
Keyword(s):  
Process Analysis ◽  
Three Dimensional ◽  
Rolling Process ◽  
Device Design ◽  
Forming Process ◽  
Dimensional Surface

Rolling Process for the Continuous Forming of Curved Surface Parts Based on Bended Rolls

2013 ◽  
Vol 684 ◽  
pp. 334-337
Author(s):  
Zhong Yi Cai ◽  
Mi Wang ◽  
Ming Zhe Li
Keyword(s):  
Convex Surface ◽  
Three Dimensional ◽  
Rolling Process ◽  
Forming Process ◽  
Continuous Forming ◽  
Metal Forming Process ◽  
Longitudinal Bending ◽  
Roll Gap ◽  
Curved Surface Parts ◽  
Dimensional Surface

A new sheet metal forming process which can form three-dimensional surface rapidly, effectively and with lower-cost has been proposed. This paper mainly focuses on the fundamental aspects of the process. The principle of the rolling process based on bended rolls is introduced, and the methods to calculate the longitudinal bending deformation and to design the roll gap are presented. Experiments for typical surface parts are carried out. The forming results of convex surface and saddle shaped surface parts are measured and analyzed, the analyzed results demonstrated that the proposed process is a feasible and effective way of forming three-dimensional surface parts.

FEM Simulation Analysis of Cross Wedge Rolling Process

2011 ◽  
Vol 381 ◽  
pp. 72-75
Author(s):  
Bin Li
Keyword(s):  
Simulation Analysis ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Rolling Process ◽  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Pressure Distributions ◽  
Metal Forming Process ◽  
Rolling Load

This paper investigates the interfacial slip between the forming tool and workpiece in a relatively new metal forming process, cross-wedge rolling. Based on the finite elements method, three-dimensional mechanical model of cross wedge rolling process has been developed. Examples of numerical simulation for strain, stress distributions and rolling load components have been included. The main advantages of the finite element method are: the capability of obtaining detailed solutions of the mechanics in a deforming body, namely, stresses, shapes, strains or contact pressure distributions; and the computer codes, can be used for a large variety of problems by simply changing the input data.

Numerical Investigation of Continuous Roll Forming for Three-Dimensional Surface Parts

2013 ◽  
Vol 849 ◽  
pp. 287-290
Author(s):  
Mi Wang ◽  
Zhong Yi Cai ◽  
Zhou Sui ◽  
Ming Zhe Li
Keyword(s):  
New Technology ◽  
Three Dimensional ◽  
Simplified Model ◽  
Roll Forming ◽  
Middle Region ◽  
Forming Process ◽  
Shaped Part ◽  
Roll Gap ◽  
Roll Forming Process ◽  
Dimensional Surface

Continuous roll forming is a new technology for manufacturing three-dimensional surface parts. Extensive numerical simulations of continuous roll forming process were carried out. The influence of the middle curve and the magnitude of the roll gap on the longitudinal curvature of formed parts is investigated. Wrinkling is one of the most important defects for the formed parts in continuous roll forming process. A simplified model was established for analyzing the wrinkling of saddle-shaped part and torus-shaped part. The simulated results show that the wrinkling of saddle-shaped part is located at the edges, and the wrinkling of torus-shaped part emerges in the vicinity of middle region.

Discussion on Finite Element Model for Three Dimensional Rolling Process Analysis

2014 ◽  
Vol 496-500 ◽  
pp. 452-455
Author(s):  
Chi Chih Shen
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Finite Element ◽  
Theoretical Model ◽  
Process Analysis ◽  
Three Dimensional ◽  
Element Model ◽  
Rolling Process ◽  
Strip Rolling ◽  
Rigid Matrix

A three dimensional numerical simulation model of metal rolling formation is developed from the theoretical model. In this theoretical model, the two variables of element deformation and temperature variation are placed in a variable matrix. The thermal elastic plastic rigid matrix and heat transfer rigid matrix are placed in the same expansion rigid matrix. Furthermore, the numerical simulation analytical model developed in this paper was used to simulate aluminum strip rolling.

Development of 3D FE Models for Incremental Forming Process Analysis of UOE Linepipes

2020 ◽  
Author(s):  
Shuwen Wen ◽  
Jun Li ◽  
Zhuozhi Fan ◽  
Shu Yan Zhang ◽  
Peng Zhang ◽  
...  
Keyword(s):  
Incremental Forming ◽  
Process Analysis ◽  
Three Dimensional ◽  
Longitudinal Direction ◽  
Transitional Zone ◽  
Detailed Examination ◽  
Forming Process ◽  
Pipe Expansion ◽  
Working Length ◽  
Deformation Features

Abstract Three dimensional (3D) FE models have been developed for simulation of the incremental forming processes employed in UOE linepipe manufacturing at Tata Steel Hartlepool 42” Pipe Mill, namely edge crimping (C-press) and pipe expansion (expander). Transitional zone behaviour resulted from both forming operations as previously identified in practice has been revealed, for the first time, by the 3D FE simulations and preliminarily analysed. It was demonstrated that the transitional zone features observed in both edge crimping and pipe expansion were initiated in the plate/pipe feed-in side/area of the dies, and then formed within the working length/face of the forming dies. Detailed examination and analysis of the FE results, in terms of plastic strain and residual stress patterns as well as contact pressure distributions, have shown that the initiation of the transitional zone features was due to the redundant plastic deformation caused by (cantilever) bending in the material feed-in area of the dies mainly along the longitudinal direction. It is therefore believed that minimisation/elimination of such redundant plastic bending effect in the longitudinal direction would lead to minimisation/elimination of the unfavourable deformation features in the so-called transitional zones, which could be achieved through improved die designs and possibly forming process parameter settings.

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