Influence of deformation path on the forming effect in a multistep flexible rolling process

Abstract

The flexible rolling process (FRP) is a novel three-dimensional (3D) forming process that combines the multipoint and traditional rolling forming. The principle of FRP is based on thickness thinning, so the deformation path significantly impacts the forming effect. In this study, the multistep forming process with different deformation paths was introduced to improve the forming effect of FRP. For instance, with the convex surface part, three finite element models of multistep FRP (MSFRP) were established. The corresponding numerical simulations and forming experiments performed among different deformation paths showed the surface part with a longer effective forming region was obtained and the forming regions with more steps in MSFRP were smoother. Thus, the sheet-metal utilization rate was greatly improved. Moreover, the MSFRP can improve the longitudinal bending effect dramatically and thereby endowing the forming part with a better forming effect. Therefore, MSFRP is a prospective method for broad applications.

Keywords

3D surface forming / multistep flexible rolling / numerical simulation / deformation path / forming effect

References

[1] Yamashita I., Yamakawa T. Apparatus for Forming Plate with a Double–Curved Surface, 1988

[2] Iseki H., Naganawa T. Vertical wall surface forming of rectangular shell using multistage incremental forming with spherical and cylindrical rollers. J. Mater. Process. Technol., 2002

[3] Luo J., Wu B., Li M.Q. 3D finite element simulation of microstructure evolution in blade forging of Ti–6Al–4V alloy based on the internal state variable models. Int. J. Miner. Metall. Mater., 2012, 19(2): 122.

[4] Jabbari M., Davami P., Varahram N. Numerical modeling and experimental validation of microstructure in gray cast iron. Int. J. Miner. Metall. Mater., 2012, 19(10): 908.

[5] Li Y., Jiang Z., Li F. Analysis of rolling force model in cold rolling mill. Rev. Metall., 2009, 106(2): 69.

[6] Yoon S.J., Yang D.Y. Development of a highly flexible incremental roll forming process for the manufacture of a doubly curved sheet metal. CIRP Ann.–Manuf. Technol., 2003, 52(1): 201.

[7] Yoon S.J., Yang D.Y. An incremental roll forming process for manufacturing doubly curved sheets from general quadrilateral sheet blanks with enhanced process feature. CIRP Ann.–Manuf. Technol., 2005, 54(1): 221.

[8] Shim D.S., Yang D.Y., Kim K.H., Han M.S., Chung S.W. Numerical and experimental investigation into cold incremental rolling of doubly curved plates for process design of a new LARS (line array roll set) rolling process. CIRP Ann.–Manuf. Technol., 2009, 58(1): 239.

[9] Shim D.S., Yang D.Y., Kim K.H., Chung S.W., Han M.S. Investigation into forming sequences for the incremental forming of doubly curved plates using the line array roll set (LARS) process. Int. J. Mach. Tools Manuf., 2010, 50(2): 214.

[10] Li M.Z., Hu Z.Q., Cai Z.Y., Gong X.P. Method of efficient continuous plastic forming for freeform surface part. J. Jilin Univ. (Eng. Technol. Ed.)., 2007, 37(3): 489.

[11] Li M.Z., Cai Z.Y., Li R.J., Lan Y.W., Qiu N.J. Continuous forming method for three–dimensional surface parts based on the rolling process using bended roll. J. Mech. Eng., 2012, 48(14): 44.

[12] Cai Z.Y., Li M.Z., Lan Y.W. Three–dimensional sheet metal continuous forming process based on flexible roll bending: Principle and experiments. J. Mater. Process. Technol., 2012, 212(1): 120.

[13] Cai Z.Y., Li M.Z. Principle and theoretical analysis of continuous roll forming for three–dimensional surface parts. Sci. China Technol. Sci., 2013, 56(2): 351.

[14] Li R.J., Li M.Z., Qiu N.J., Cai Z.Y. Surface flexible rolling for three–dimensional sheet metal parts. J. Mater. Process. Technol., 2014, 214(2): 380.

[15] Su Z., Cai Z.Y., Lan Y.W., Liu L. Simulation and software design of continuous flexible roll bending process for three dimensional surface parts. Mater. Des., 2014, 54, 498.

[16] Wang D.M., Li M.Z., Cai Z.Y. An investigation on roll adjusting radius in three–dimensional rolling process for three–dimensional surface parts, Proc. IMechE. Part B: J. Eng. Manuf., 2014, 229(5): 761.

[17] Wang D.M., Li M.Z., Cai Z.Y. Continuous–forming method for three–dimensional surface parts combining rolling process with multipoint–forming technology. Int. J. Adv. Manuf. Technol., 2014, 72(1–4): 201.

[18] Ma J.W., Yang C.P., Zheng Z.H., Zhang K.S., Ma W.Y. Influence of process parameters on the microstructural evolution of a rear axle tube during cross wedge rolling. Int. J. Miner. Metall. Mater., 2016, 23(11): 1302.

[19] Jiang H.T., Liu J.X., Mi Z.L., Zhao A.M., Bi Y.J. Texture evolution of commercial pure Ti during cold rolling and recrystallization annealing. Int. J. Miner. Metall. Mater., 2012, 19(6): 530.

[20] Wang X.C., Yang Q., Du X.Z., Jiang Z.Y. Allowable variation of cold–rolled strip transverse profiles in high tension. Int. J. Miner. Metall. Mater., 2010, 17(5): 608.