Numerical Simulation of a New Stretch Forming Process: Multi-Roll Stretch Forming Process

Abstract

Multi-roll stretch forming process (MRSF) is a flexible manufacturing technique to form sheet panels with different curvature. More importantly, the flexible rollers play the role of a nucleus in MRSF. Compared with the traditional stretch forming, MRSF is better industrially applicable to not only the traditional dies but also the Multi-point stretching die (MPSD). In this paper, extensive numerical simulations of the MRSF process of stretching toroidal saddle parts were carried out based on the dynamic explicit finite element analysis. And for the flexible rollers, the analysis of lateral rollers position and discreteness of rollers are used to study the effect of flexible rollers on the quality of formed part. The investigation shows that the two aspects are quite critical for the quality of formed parts.