Study on flexibly-reconfigurable roll forming process for multi-curved surface of sheet metal

2014 ◽  
Vol 15 (6) ◽  
pp. 1069-1074 ◽  
Author(s):  
Jun-Seok Yoon ◽  
So-Eun Son ◽  
Woo-Jin Song ◽  
Jeong Kim ◽  
Beom-Soo Kang
Keyword(s):  
Sheet Metal ◽  
Curved Surface ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Modeling and Simulation of Continuous Flexible Roll Forming Process

2013 ◽  
Vol 365-366 ◽  
pp. 549-552
Author(s):  
Zhou Sui ◽  
Zhong Yi Cai ◽  
Ming Zhe Li
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Rigid Bodies ◽  
Roll Forming ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Roll Forming Process

The continuous flexible roll forming process is a novel sheet metal forming technique for effectively manufacture of three-dimensional surface parts. In this study, two types of finite element (FE) models were developed under the ABAQUS/Explicit environment. The difference of the two models is that the rolls are defined as discrete rigid bodies in model No.1 and are deformable in model No.2. An experiment was carried out using the continuous sheet metal forming setup. The comparison of the numerical computation results with the experimental results shows that the model No.2 can be used for the shape prediction of continuous flexible roll forming process well.

A New Engineering Technique in Roller Design to Prevent Thinning of Sheet in Roll Forming Process

2017 ◽  
Vol 873 ◽  
pp. 42-47
Author(s):  
Dong Won Jung
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Metal Sheet ◽  
Roll Forming ◽  
Forming Process ◽  
Explicit Finite Element ◽  
Main Challenge ◽  
Engineering Technique ◽  
Roll Forming Process

These days sheet metal forming is a widely used in different industrial fields with large production volumes. Formability of metal sheets is limited by localized necking and plastic instability. In sheet metal forming processes like drawing and stamping the main challenge is thinning of the metal sheet in some regions. To reduce thinning of the sheet product, roll forming has been suggested instead of stamping process. Thinning strain can cause necking, tearing or wrinkling which are failure of the metal sheet. In this study a new engineering technique is proposed in order to prevent thinning of the steel galvanized hot coil commercial (SGHC) in roll forming process. An explicit finite element code, ABAQUS software, was used to simulate the roll forming process. The results show that the proposed technique has an important effect on thinning of the sheet and can reduce it significantly. Investigation on the second and third and fourth rollers show the effect of modified roller dimension as on reducing the thickness. These reductions in second, third and fourth rollers are from 4 percent to 0.5 percent, 2.8 to 1.4 percent and from 1.4 to 0.7 percent respectively. The reasons of the new techniques effect were also discussed.

A novel continuous roll forming process of sheet metal based on bended rolls

2014 ◽  
Vol 73 (9-12) ◽  
pp. 1807-1814 ◽  
Author(s):  
Zhong-Yi Cai ◽  
Dong-Bo Guan ◽  
Mi Wang ◽  
Ming-Zhe Li
Keyword(s):  
Sheet Metal ◽  
Roll Forming ◽  
Forming Process ◽  
Roll Forming Process

Deformation Characteristics of the Sheet Metal in the Roll Gap for the Continuous Roll Forming Process

2018 ◽  
Vol 932 ◽  
pp. 3-7
Author(s):  
Mi Wang ◽  
Shu Chen Yang ◽  
Guo Long Lu
Keyword(s):  
Sheet Metal ◽  
Friction Force ◽  
Coulomb Friction ◽  
Roll Forming ◽  
Deformation Characteristics ◽  
Forming Process ◽  
Surface Part ◽  
Coulomb Friction Law ◽  
Roll Gap ◽  
Roll Forming Process

Continuous Roll Forming process (CRFP) is a newly developed technique applied to form 3D surface part with various transverse and longitudinal curvatures. In CRFP, the sheet metal is non-uniformly compressed in the roll gap between the upper and lower bendable rolls. The two bendable rolls rotate in opposite directions, and the sheet metal is bitten into the roll gap continuously. At the present, the deformation characteristics of the sheet metal in the deformation zoon (sheet metal between the upper and lower bendable roll) is discussed. The friction force in CRFP can be calculated according to the Coulomb friction law.

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