Design of the flexibly-reconfigurable roll forming process by a progressively-improving goal seeking approach

Ghiabakloo, Hadi; Park, Ji-Woo; Kil, M. G.; Lee, Kyung-Hoon; Kang, Beom-Soo

doi:10.1016/j.ijmecsci.2019.04.020

Cited by 14 publications

(4 citation statements)

References 41 publications

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“…From Equation (21) to Equation (23), it is found that the expressions of p and q can be written as follows:…”

Section: Modification Of the Formula For Calculating The Longitudinal Curvature Radius Of Saddle Surfacementioning

confidence: 99%

“…Park et al [20] established a regression model and an artificial neural network model to predict the longitudinal curvature radius, and it was found that the regression model is more suitable for the prediction of convex parts, and the artificial neural network model is more suitable for the prediction of saddle parts. Ghiabakloo et al [21] used the finite element method and genetic algorithm to calculate the longitudinal curvature radius. Cai et al [22][23][24] analyzed the mechanism of the longitudinal bending deformation of the sheet metal from a mechanics perspective, and put forward the necessary condition of CRF; that is, the longitudinal strain is the first-order function of coordinates.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

Gao

Sun

et al. 2020

Metals

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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.

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“…From Equation (21) to Equation (23), it is found that the expressions of p and q can be written as follows:…”

Section: Modification Of the Formula For Calculating The Longitudinal Curvature Radius Of Saddle Surfacementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

Gao

Sun

et al. 2020

Metals

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show abstract

“…The doubly-curved surface rolling process based on the line forming method, due to its high production e ciency, low equipment cost, and good surface quality of the formed surfaces [5] , has attracted the attention of many scholars in recent years. In 1988, Yamashita and Yamakawa [6] rst proposed the use of roll forming to manufacture doubly-curved surfaces.…”

Section: Introductionmentioning

confidence: 99%

The effects of central cross-section diameters of rollers on doubly curved surface rolling

Chang

et al. 2023

Int J Adv Manuf Technol

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During the rolling of doubly-curved sheet metal surfaces, the ow of metal is very complicated and will affect by the dimension of rolling deformation zone. The dimension of rolling deformation zone is mainly affected by the rolling reduction and the central cross-section diameter of the rollers. In this paper, the in uence of central cross-section diameter of the rollers on the longitudinal bending deformation of formed spherical surfaces and the stability of the rolling process is studied combined with the rolling reduction. The current research results show that the larger the central cross-section diameter of the rollers, the more stable the rolling process, and the better the shape accuracy of the formed spherical surface. When the central cross-section diameter of the rollers is relatively small, the longitudinal bending deformation of the formed spherical surface increases with the increase of the central cross-section diameter of the rollers. However, an excessively large roller diameter will restrain the longitudinal bending deformation of the sheet. When the central cross-section diameter of the rollers is relatively large, the longitudinal bending deformation of the formed spherical surface will decrease with the increase of the central cross-section diameter of the rollers. The results in this study can be used as a reference for the design of roller to ensure that the formed doubly-curved surface can obtain greater longitudinal bending deformation and better shape accuracy under the same rolling reduction.

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“…Yoon et al [ 21 ] established a prediction model of longitudinal curvature radius by defining deformation vectors. For the purpose of improving the efficiency and accuracy of the prediction, Ghiabakloo et al [ 22 , 23 , 24 ] decomposed the shape prediction into three regions, namely pre-rolling, rolling, and post-rolling, each of which was solved by an appropriate method. Park et al [ 25 , 26 ] constructed a regression model and an artificial neural network model, respectively, and they proved that the regression model is suitable for convex surfaces, and the artificial neural network model performs better while producing saddle surfaces after comparison.…”

Section: Introductionmentioning

confidence: 99%

Shape Prediction of the Sheet in Continuous Roll Forming Based on the Analysis of Exit Velocity

et al. 2021

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Continuous roll forming (CRF) is a new technology that combines continuous forming and multi-point forming to produce three-dimensional (3D) curved surfaces. Compared with other methods, the equipment of CRF is very simple, including only a pair of bendable work rolls and the corresponding shape adjustment and support assembly. By controlling the bending shapes of the upper and lower rolls and the size of the roll gap during forming, double curvature surfaces with different shapes can be produced. In this paper, a simplified expression of the exit velocity of the sheet is provided, and the formulas for the calculation of the longitudinal curvature radius are further derived. The reason for the discrepancy between the actual and predicted values of the longitudinal radius is deeply discussed from the perspective of the distribution of the exit velocity. By using the response surface methodology, the effects of the maximum compression ratio, the sheet width, the sheet thickness, and the transverse curvature radius on the longitudinal curvature radius are analyzed. Meanwhile, the correction coefficients of the predicted formulas for the positive and negative Gaussian curvature surfaces are obtained as 1.138 and 0.905, respectively. The validity and practicability of the modified formulas are verified by numerical simulations and forming experiments.

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Design of the flexibly-reconfigurable roll forming process by a progressively-improving goal seeking approach

Cited by 14 publications

References 41 publications

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

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

The effects of central cross-section diameters of rollers on doubly curved surface rolling

Shape Prediction of the Sheet in Continuous Roll Forming Based on the Analysis of Exit Velocity

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