Analytical and Numerical Investigation of Four-roll Bending

Document Type : Persian

Authors

1 Lecturer, Mechanical Engineering Department, Islamic Azad University, Khomeinishahr Branch.

2 - Lecturer, Islamic Azad University, Tiran Branch

Abstract

Four-roll bending process is usually used for manufacturing of seamed thick-walled and thin-walled cylinders. Due to complexity of this process, the analytical solution of plate bending in this process has not been developed completely. The existence of friction and multi-step processing makes it more difficult. Investigation of four-roll bending process using analytical and numerical methods is the main aim of current research. At first, using plate deformation theories, an analytical solution for four-roll bending process is extracted. By decomposing the deformation to elastic and elasto-plastic, the required bending moment is calculated. Considering the distribution of bending moment along the plate, the radius of bending is calculated considering spring back effects. The four-roll bending process is simulated by the finite element method. The simulation results show that the level of strain is less than the critical value and hence there are no damaged parts in the plate during process. Besides, bending radius of the plate after spring back is calculated and compared with the analytical values. Finally, for validation of analytical and numerical results, some experiments were conducted on aluminum. Results of this research show that both analytical and numerical methods are proper techniques for predicting plate behavior during four-roll bending.

Keywords

References

[1]  Gandhi A.H., Raval H.K., Analytical and empirical modeling of top roller position for three-roller cylindrical bending of plates and its experimental verification, Journal of Materials Processing Technology, Vol. 197, (1-3), 2008, pp. 268-278.
[2]  Gu X., Franzke M., Bambach M., Hirt G., Experimental and numerical investigation of grid sheet bending behavior in four-roll bending, CIRP Annals - Manufacturing Technology, Vol. 59, (1), 2010, pp 303-306.
[3] Feng Z., Champliaud H., Three-stage process for improving roll bending quality, Simulation Modelling Practice and Theory, Vol. 19, (2), 2011, pp. 887-898.
[4]  Hua M., Sansome D.H., Baines K., Mathematical modeling of the internal bending moment at the top roll contact in multi-pass four-roll thin-plate bending, Journal of Materials Processing Technology, Vol. 52, 1995, pp. 425-459.
[5]  Hua M. , Cole I.M., Baines K., A formulation for determining the single-pass mechanics of the continuous four-roll thin plate bending process, Journal of Materials Processing Technology, Vol. 67, 1997, pp. 189-194.
[6] Hua M., Baines K., Cole I.M., Continuous four-roll plate bending: a production process for the manufacture of single seamed tubes of large and medium diameters, International Journal of Machine Tools and Manufacture, Vol. 39, Issue 6, 1999, pp. 905-935.
[7] Lee S. M., Shivpuri R., Investigation of two square-to-round multipass rolling sequences by the slab-finite-element method, Int. J. Mach. Tools Mf., Vol. 32, 1992, pp. 315-327.
[8] Zeng J., Liu Zh., Champliaud H., FEM dynamic simulation and analysis of the roll-bending process for forming a conical tube, Journal of Materials Processing Technology, Vol. 198, Issue 1-3, 2008, pp. 330-343.
[9] Brunet M., Mguil S., Pol P., Modeling of a roll-forming process with a combined 2D and 3D FEM code, Journal of Materials Processing Technology, Vol. 80, 1998, pp. 213-219
[10] Li Zh., Yang H., Li H., Xu J., An accurate 3D-FE based radius prediction model for in-plane roll-bending of strip considering spread effects, Computational Materials Science, Vol. 50, Issue 2, 2010, pp. 666-677.
[11]      Weinmann K.J., Rosenberger A.H., Sanchez L.R., Turkovich B.F., The Bauschinger Effect of Sheet Metal Under Cyclic Reverse Pure Bending, CIRP Annals - Manufacturing Technology, Vol. 37, Issue 1, 1988, pp. 289-293
[12] Hemmerich E., Rolfe B., Hodgson P.D., Weiss M., The effect of pre-strain on the material behaviour and the Bauschinger effect in the bending of hot rolled and aged steel, Materials Science and Engineering: A, Vol. 528, Issue 9, 2011, pp. 3302-3309.
 
Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering
Volume 3, Issue 1 - Serial Number 1
September 2010
Pages 47-58

Files

Share

How to cite

Statistics