scholarly journals Prediction of Longitudinal Curvature Radius of 3D Surface Based on Quadratic Relationship between Strain and Coordinates in Continuous Roll Forming

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1249
Author(s):  
Jiaxin Gao ◽  
Dongye He ◽  
Lirong Sun ◽  
Xi Zhang ◽  
Zhongyi Cai
Keyword(s):  
Convex Surface ◽  
Design Method ◽  
Three Dimensional ◽  
Roll Forming ◽  
Curvature Radius ◽  
Forming Process ◽  
3D Surface ◽  
Quadratic Relationship ◽  
Relative Errors ◽  
Roll Gap

Continuous roll forming (CRF) is a new method for the rapid forming of three-dimensional (3D) surfaces developed in recent years, and the significant advantage of CRF compared with traditional die forming is that the longitudinal dimension of the sheet metal is not limited. By controlling the curvature radius and gap shape of upper and lower bending rolls, three-dimensional parts with different shapes and sizes can be precisely formed. When the elastic deformation is ignored during the forming process, the transversal curvature radius of the three-dimensional surface is consistent with the radius of the roll gap centerline. Therefore, the calculation of longitudinal curvature radius is the key to improve the accuracy of the 3D surface in CRF. In this paper, the basic principle of CRF is described. The modified formulas for calculating the longitudinal curvature radius of convex and saddle surfaces based on the quadratic relationship between the strain and coordinates are deduced in detail, and the corresponding design method of the roll gap is derived. Furthermore, the mathematical equations of convex and saddle surfaces are given. Through numerical simulation and theoretical analysis, it is found that the relative errors of the longitudinal centerline radius are reduced from 13.67% before modification to 4.35% after modification for a convex surface and 6.81% to 0.41% for a saddle surface when the transversal curvature radius is 800 mm and the compression ratio is 5%. The experimental and measured results indicate that the shapes of formed parts are more consistent with the target parts after modification, which further proves the applicability of the modified formulas.

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.

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.

Derivative Design of Axial Fan Range: From Academia to Industry

2016 ◽  
Author(s):  
Tommaso Bonanni ◽  
Lucio Cardillo ◽  
Alessandro Corsini ◽  
Giovanni Delibra ◽  
Anthony G. Sheard ◽  
...  
Keyword(s):  
Performance Prediction ◽  
Good Accuracy ◽  
Design Method ◽  
Three Dimensional ◽  
Correct Prediction ◽  
Preliminary Design ◽  
Axial Fan ◽  
Data Set ◽  
Axial Fans ◽  
Relative Errors

The work presented in this paper concerns a useful method for axial fans preliminary design based on the “Derivative Design” concept. The emphasis is, on one side, on education and, on the other, on the practical help that such method can provide in the early preliminary design process. A complete data set of an axial fan measured with ISO 5801 standards is the start point for the investigation and the prediction of the multiple possible performance that different fan configurations can provide, in terms of dimensionless duty coefficients. In particular, configurations with different number of blades, and hence of solidity, are studied. The typical options of derivative design are explored and relations for performance prediction are presented. A detailed description of the derivative design methodology is followed by tests and validation. The tools employed are a fully three dimensional code, the Advanceded Actuator Disk Mode (AADM), and two other in-house codes, the Meanline Axisymmetric Calculation (MAC) and Axisymmetric Laboratory (AXLAB). Results of the derivative design method are reported, showing a good accuracy against the AADM data. The MAC and AXLAB ensure still acceptable results when increasing the solidity of the machine. On the contrary, a decrease of solidity leads to higher relative errors in the prediction of the load coefficient. In conclusion, an exploration of the possible fields of operation of a blade profile can be carried out by a correct prediction of the stage diffusion factor.

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.

Study on Spring-Back Effect according to Roll Gap and Forming Velocity of Roll Forming Process

2016 ◽  
Vol 33 (6) ◽  
pp. 477-483
Author(s):  
Dong Hong Kim ◽  
Dae-Hwan Yoon ◽  
Sang-Seok Seol ◽  
Dong Won Jung
Keyword(s):  
Roll Forming ◽  
Spring Back ◽  
Forming Process ◽  
Roll Gap ◽  
Roll Forming Process

Dynamic Analysis of 3D Roll Forming Equipment in Mechanical System

2013 ◽  
Vol 740 ◽  
pp. 323-331 ◽  
Author(s):  
Zhen Feng Yang ◽  
Qiang Li ◽  
Yan Zhi Guan
Keyword(s):  
Differential Equations ◽  
High Strength Steel ◽  
Dynamic Balance ◽  
Three Dimensional ◽  
Mechanical Systems ◽  
High Strength ◽  
Roll Forming ◽  
System Response ◽  
Forming Process ◽  
Element Simulation

In this paper, the high-strength steel three-dimensional roll forming production line prototype is studied. The dynamic differential equations of 3D roll forming machine mechanical systems are established by the principle of dynamic balance. The dynamic differential equations are solved out by using MATLAB with the engineering example finite element simulation data. The dynamic characteristics of the forming process of 1.5mm TRIP590 high-strength steel sheet are obtained by the System response. The results can help to improve the performance of the prototype mechanical systems.

Numerical Simulation and Experiment Research on Surface Defects for Thick Plate Multi-Point Forming Process

2013 ◽  
Vol 385-386 ◽  
pp. 59-62
Author(s):  
Le Li ◽  
Li Yong Wang
Keyword(s):  
Flexible Manufacturing ◽  
Surface Defects ◽  
Three Dimensional ◽  
Metal Plate ◽  
Curvature Radius ◽  
Forming Process ◽  
Explicit Finite Element ◽  
Deformation Features ◽  
Simulation And Experiment ◽  
Forming Defects

Multi-point forming (MPF) is an advanced flexible manufacturing technology for three-dimensional sheet metal forming. The substance of MPF is replacing the conventional solid dies by a set of discrete punches called punch group. Due to the discrete contacts between the workpiece and punches, the dimple defects occurred, which are inevitable and particular for MPF. In this study, the analysis of the deformation features of the dimple defects was implemented. The dynamic explicit finite element method was chosen to implement the simulation of MPF process. The influencing factors of the surface defects were researched. The relevant experiment was implemented, and it verified that the forming defects decreased with the increasing of the thickness of metal plate and the objective surface curvature radius.

Data-driven affective product design using complete three-dimensional surface data

2021 ◽  
pp. 1-19
Author(s):  
Zeng Wang ◽  
Weidong Liu ◽  
Minglang Yang
Keyword(s):  
Mathematical Model ◽  
Product Design ◽  
Design Method ◽  
Three Dimensional ◽  
Automatic Generation ◽  
Generative Model ◽  
Data Driven ◽  
Recognition Model ◽  
3D Surface ◽  
Surface Data

As the main part of design display and evaluation, product three-dimensional (3D) form is the core object in affective product design. However, previous research has not yet addressed the development of technical models and method involving complete 3D surface data, and thus cannot guarantee the quality of affective product design. By using the techniques of triangular mesh model, spherical harmonic and conditional variational auto-encoder, this paper proposes a data-driven affective product design method composed of several technical models using complete 3D surface data. These models include: mathematical model for quantifying 3D form, recognition model for recognizing customer’s affective responses, and generative model for generating new 3D forms. For affective product design, the mathematical model achieves the acquisition and processing of complete 3D surface data, the recognition model improves the objectivity and accuracy of recognition by integrating the 3D form data into the calculation process of emotion recognition, and the generative model realizes the automatic generation of new 3D forms in response to emotional data based on the recognition results. Each model provides technical support for realizing the acquisition, processing and generation of complete 3D surface data of product form, and ensures the systematic and completeness of the proposed method for the affective product design involving 3D form innovation. The feasibility of the method is verified by an example of car design, and the results show that it is an effective affective product design method involving 3D form innovation.

Experimental Investigation and Research on Forming Process of Micro Flat-Wire

2010 ◽  
Vol 37-38 ◽  
pp. 417-423
Author(s):  
Chun Chiu Fok ◽  
Zhong Ning Guo ◽  
Zhao Qin Yu ◽  
Jian Wen He
Keyword(s):  
Rolling Process ◽  
Rolling Speed ◽  
Roll Forming ◽  
Wire Surface ◽  
Forming Process ◽  
Forming Technology ◽  
Rolling Method ◽  
The Wire ◽  
Roll Gap ◽  
Control Part

The aim of this study is to get a better understanding of Micro Flat-Wire Roll Forming Technology. There are three methods for Mirco flat-wire forming, i.e., drawing, extrusion, and rolling. Without replacing the equipment, rolling method only demands to adjust the relative roll gap between the pressure and the wire deformation that it can produce different specifications of mirco flat-wire. The rolling equipment was introduced and can be divided into three parts, the mechanism section, the control part and the wire-locating device. Furthermore, the rolling process parameters were summarized as well. The effect of rolling amount and rolling speed on the wire surface quality was also discussed.

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