Abstract
A flexible roll forming machine was designed and made using CAD/CAE technologies. The Ethernet control system was adopted to control the motions of forming rolls and stands simultaneously. The forming path was generated in according to the longitudinal roll forming profile of the product geometry. The blank position was monitored using measuring wheel encoders to compensate the blank shifting error. The CAE simulations were carried out to evaluate the feasibility of the process and die designs. The roll-formed part was measured by the experiment tests. The experimental results had shown the error compensation proposed was able to reduce shifting error from 4 mm to 0.5 mm.
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