Effect of the arc profile roll gap on forming results in flexible rolling process

Abstract

Flexible rolling is a new-style process, it is suitable to produce the small batch and various size forming parts. In this paper, a new design scheme of roll gap was applied to form spherical surface. Two arc with different curvature radius are used as the upper and lower profile of the roll gap. Theoretically, the smooth and continuous arc can’t cause instability and wrinkling in the local area of sheet metal. Based on the process of flexible rolling, the finite element model was established, and the boundary conditions were determined. The forming process of spherical surface formed by arc profile roll gap was simulated. The results show that: By simulating forming process, the forming part is smooth without forming defects, the forming quality is better, it verifies the feasibility of the application.