Abstract
3D rolling is a novel forming process for manufacturing 3D surface parts by employing a pair of forming rolls as a forming tool. By controlling the nonuniform distribution of roll gap of the forming rolls, residual stress of the sheet metal makes the sheet metal bend in the transverse and longitudinal directions simultaneously. As the roll adjusting radius is much larger than the target transverse curvature radius of the forming surface, the forming roll could rotate around its axis easily, which is suitable for producing 3D surface parts including the wide sheet metal with relatively small transversal curvature radius. In this paper, different roll adjusting radii are investigated for 3D surface parts, and the 3D rolling process has been improved to increase the length of effectively forming region of the forming parts and improve the utilization rate of sheet metal. Finite element analysis models are established; spherical and saddle surfaces are simulated. The corresponding experimental results are obtained. The dimensional accuracy of the forming part is measured, and the differences of the forming processes are analyzed by comparing the simulated results. The comparison and analysis of the forming results show the feasibility of the improved method of 3D rolling process for 3D surface parts.
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Wang, D., Li, M., Wang, Y. et al. Investigation and improvement of 3D rolling process for 3D surface parts. Int J Adv Manuf Technol 78, 407–417 (2015). https://doi.org/10.1007/s00170-014-6687-5
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DOI: https://doi.org/10.1007/s00170-014-6687-5