Research on rolling different types of 3D curved parts by small adjustments in rolling reduction

• Published in: International journal of advanced manufacturing technology Vol. 119; no. 9-10; pp. 6235 - 6244
• Main Authors: Chang, Xiang, Fu, Wenzhi, Li, Mingzhe, Wang, Xintong, Yang, Weifeng, Deng, Yushan
• Format: Journal Article
• Language: English
• Published: London Springer London 01-04-2022; Springer Nature B.V
• Subjects: Advanced manufacturing technologies; Bending; CAE) and Design; Computer-Aided Engineering (CAD; Curvature; Deformation; Engineering; Finite element method; Forming; Industrial and Production Engineering; Manufacturing; Mechanical Engineering; Media Management; Original Article; Rapid manufacturing; Reduction; Roll gap; Rollers; Rolling; Flexible forming; Numerical simulation; 3D curved part
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-08519-9

The 3D curved parts rolling based on rigid arc-shaped rollers is a novel plastic forming process for rapidly manufacturing curved parts with double curvature. This work proved that the method can form different types of 3D curved parts through small adjustments of the rolling reduction without replacing the rollers. The study found that when the generatrix radius of the convex roller is smaller than that of the concave roller, the distribution rule of uneven roll gap could vary with the change of the rolling reduction. Therefore, the forming method can change the distribution rule of uneven roll gaps by adjusting the rolling reduction to form different types of curved parts (spherical parts, saddle-shaped parts, or cylindrical parts). The relationship between the rolling reduction and the distribution rule of roll gaps is studied by analytical, finite element, and experiment method. And the influence of the rolling reduction on the bending deformation of different types of curved parts is studied. The research results show that the longitudinal bending deformation of formed curved parts is greatly affected by the rolling reduction. The longitudinal curvature of formed saddle-shaped parts decreases with the increase of the rolling reduction, and the longitudinal curvature of formed spherical parts increases with the increases of the rolling reduction. The transverse bending deformation of formed curved parts is little affected by the rolling reduction.