Influence of Process Parameters on the Forward Slip of Cup during Roll Forming

Abstract

The effect of friction coefficient, reduction of thickness, forming speed, roller diameter on the coefficient of forward slip at the rim of the roller during cup roll forming was studied by numerical simulation. The results show that during roll pre-forming, the friction coefficient and forming speed have little effect on the coefficient of forward slip, and the reduction of thickness and the diameter of the roller have a greater influence on the coefficient of forward slip; as the reduction of thickness increases, the coefficient of forward slip increases; as the roller diameter increases, the coefficient of forward slip increases first and then decreases. The coefficient of forward slip during the roll pre-forming of cup is much larger than that of roll forging. During roll shaping, the process parameters have little effect on the coefficient of forward slip and its value is close to zero, that is, the axial length of the roll shaped part is almost equal to the arc length of the roller rim. The accuracy of numerical simulation is verified by experiments, and the error between the numerical simulation and experiment is less than 1%.