Finite Element Analysis of Deformed Geometry in Three-Roller Plate Bending Process

Tailor, V. K.; Gandhi, Anish H.; Moliya, R. D.; Raval, Harit K.

doi:10.1115/msec_icmp2008-72439

Cited by 8 publications

(8 citation statements)

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“…Equation (12) allows for a more accurate prediction of the inner radius of the bending plate as a function of vertical displacement. Figure 12 compares the vertical displacement as a function of the inner radius of the bending plate corresponding to the geometric compatibility (as in Equation 7), the deformation compatibility (as in Equation (12)), and the FE results, for the 10-mm plate thickness.…”

Section: Radius Of the Bending Platementioning

confidence: 99%

“…However, the analytical models are not able to fully describe the complex deformation behavior of the materials during the bending process due to oversimplified assumptions [ 2 , 7 ]. Therefore, in the attempt to optimize the roll bending process, in the last years, the finite element method (FEM) was applied to simulate the bending process and extract different information, such as bending force, the radius of curvature, stress-strain state in the contact area under various conditions, and the finite element (FE) environment [ 8 , 9 , 10 , 11 , 12 , 13 ]. For example, Tran investigated the forming process of an asymmetrical roll bending machine using a three-dimensional (3D) dynamic FE model in the Ansys/LS-DYNA environment and the results were validated by experiments [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

“…Ktari et al carried out two-dimensional (2D) modeling of the rolling process in three roll bending pyramid systems using Abaqus explicit module [ 11 ]. Taylor et al investigated the influence of various parameters of the three-roll bending process on the final radius of curvature of the bent sheet using an elastoplastic explicit dynamic FE method under the LS-DYNA environment [ 12 ]. Neto et al developed an FE model to analyze the stress–strain in the vicinity of the contact area where the plastic deformation increases due to the forming tool [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

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Estimating of Bending Force and Curvature of the Bending Plate in a Three-Roller Bending System Using Finite Element Simulation and Analytical Modeling

2021

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Many industries such as shipbuilding require steel bending plates in a wide range of radii, thus bending machines are often designed and produced on a custom basis in shipyards. From a design perspective, however, the bending force and the radius of the bending plate as a function of vertical displacement of the upper roller must be known. In this paper, a hybrid numerical–analytical approach is proposed to investigate the three-roller bending process for two plates of steel used in the naval industry. Firstly, the bending process is modeled using the finite element (FE) method and regression models for the bending force as a function of plate thickness and vertical displacement of the upper roller were constructed. Then, based on the findings from FE analysis, using the bent bar theory, two analytical expressions for the bending force were derived. Using geometric and deformation compatibilities, analytical expressions for the vertical displacement of the upper roller as a function of the curvature of the bending plate were also developed. The FE results suggest that the cross section of the plate is practically a plastic hinge in the tangent area of the upper roller and that the deformation compatibilities must be considered in order to estimate the curvature radius of the bending plate using analytical formulations. These results are of practical importance in designing rolling machines to estimate the setting parameters.

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Section: Radius Of the Bending Platementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Estimating of Bending Force and Curvature of the Bending Plate in a Three-Roller Bending System Using Finite Element Simulation and Analytical Modeling

2021

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“…With the rapid development of shipbuilding, gas pipelines, aerospace, and other industries, the demand for large-scale thick-walled parts increases year by year. 1 In the actual rolling process, extra-thick plate is under the influence of many factors and its bending forming mechanism is also more complicated. In order to improve the roll forming quality and increase the processing efficiency, it is necessary to conduct an in-depth research on the roll forming process of the extra-thick plate.…”

Section: Introductionmentioning

confidence: 99%

Research on numerical simulation and process parameters of three-roll bending based on thickness characteristics of extra-thick plate

Wang

Zhao

Cui

et al. 2019

Advances in Mechanical Engineering

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Mechanism of roll forming for the extra-thick plate is more complicated, which is greatly influenced by the thickness characteristics of extra-thick plate and affects the machining accuracy of the extra-thick plate. In order to improve the forming quality of the three-roll coiling machine for the extra-thick plate, a stress-strain model with a linear distribution of the thickness is established. Based on the analysis of roll deformation of extra-thick plate, the analytical model of the three-roll rolling process is established. The stress field distribution in the bending deformation zone was analyzed with the use of ABAQUS software. The influence of the pressure on the upper roller, the friction between the roll and the sheet, and the processing speed of the sheet on the forming of the plate were analyzed. The results show that compared with the medium-thick plate, extra-thick plate appeared more obvious stress concentration in the contact area between the roll and the plate and the maximum equivalent stress increased by 15.3%. When the upper roller moves down the same distance, the roll forming curve of the extra-thick plate is basically consistent considering the thickness characteristics or not, and the maximum deviation of the forming radius is 5.7%. The forming radius is constant when the roll processing speed is between 0.15 and 0.45 rad/s, and the forming radius of the extra-thick plate is larger than that of the 30 mm medium-thick plate by 2.3%. The forming radius of the plate increases with the increase of friction coefficient between the rollers and plate. Compared to the 30-mm medium-thick plate, the forming radius of the extra-thick plate increases by 20%.

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“…K. Tailor et al [9] proposed that the pyramid type three-roller bending process it is difficult to deform the plate perfectly to the required circular shape and it mainly depends on the skill of the operator. Presented work shows the finite element (FE) simulations of three-roller plate bending process to study the influence of different parameters such as roller position, rolling speed, plate material, plate length and friction (at roller plate interfaces) on the bending quality of the deformed plate.…”

Section: Literature Reviewmentioning

confidence: 99%

STStudy of Stress Strain Curve of sheet metal by using Three Roller Bending Machine- A review

Jadhav¹,

Talmale²

2017

IJMTER

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Abstract-Roller bending process is used to transform a sheet or plate into hollow cylindrical shapes implementing plastic deformation techniques. Cylindrical and conical shells are the basic elements used for the various engineering applications like cylindrical tanks, boiler chambers, heat exchanger shells, pressure vessels and structures. In these cases, it is important to bend the sheet safely and working for longer life. In bending operation a metal sheet is subjected to sequential bending stresses for different position of top roller. Advanced techniques are used for verification of stress values up to ultimate tensile strength of material. Failure of material is detected at UTS value by visualizing the cracks.

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Finite Element Analysis of Deformed Geometry in Three-Roller Plate Bending Process

Cited by 8 publications

References 0 publications

Estimating of Bending Force and Curvature of the Bending Plate in a Three-Roller Bending System Using Finite Element Simulation and Analytical Modeling

Estimating of Bending Force and Curvature of the Bending Plate in a Three-Roller Bending System Using Finite Element Simulation and Analytical Modeling

Research on numerical simulation and process parameters of three-roll bending based on thickness characteristics of extra-thick plate

STStudy of Stress Strain Curve of sheet metal by using Three Roller Bending Machine- A review

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