Transactions of Materials Processing (소성∙가공)

The Korean Society for Technology of Plasticity and materials processing (한국소성∙가공학회)
권호 표지
DOI QR코드

DOI QR Code

Flexible Roll Forming Technology for Multi-Curved Sheet Metal Forming

다중곡률형상의 판재성형을 위한 가변롤성형 기술

  • Received : 2013.03.28
  • Accepted : 2013.06.18
  • Published : 2013.08.01
Download PDF
⟨ Previous Next ⟩

Abstract

The multi-point forming (MPF) process for three-dimensional curved sheet metal has been developed as an alternative to the conventional die forming process since MPF allows the manufacturing of various shapes using one die set and reduce the cost of production. However, the MPF process cannot provide high quality products yet due to defects occurring in the sheet such as dimples and wrinkles. It can also lead to economic loss because of long tool setup time and additional machining required outside of the sheet formed area. In this study, a new sheet metal forming method, called flexible roll forming (FRF), is proposed to solve the problems of existing processes for three-dimensional curved sheet metal. This progressive process utilizes adjusting rods, as well as upper and lower flexible rollers as forming tools. In contrast with the existing processes, FRF can reduce the additional production costs because of the possible blank size for the part longitudinal direction, which is unrestricted. In this research, methods and procedures of the flexible roll forming technology are described. Numerical forming simulations of representative three-dimensional curved sheet products are also carried out to demonstrate the feasibility of this technology.

Keywords

Acknowledgement

Supported by : 한국연구재단

References

  1. H. C. Kuo, L. J. Wu, 2002, Automation of Heat Bending in Shipbuilding, Comput. Ind., Vol. 48, No. 2, pp. 127-142. https://doi.org/10.1016/S0166-3615(02)00013-1
  2. D. E. Ko, C. D. Jang, S. I. Seo, H. W. Lee, 1999, Realtime Simulation of Deformation due to Line Heating for Automatic Hull Forming System, J. Soc. Naval Architects. Kor., Vol. 36, No. 4, pp. 116-127.
  3. M. Z. Li, Y. H. Liu, S. Z. Su, G. Q. Li, 1999, Multipoint Forming: a Flexible Manufacturing Method for a 3-D Surface Sheet, J. Mater. Process. Technol., Vol. 87, No. 1-3, pp. 277-280. https://doi.org/10.1016/S0924-0136(98)00364-1
  4. M. Z. Li, Z. Y. Cai, Z. Sui, Q. G. Yan, 2002, Multipoint Forming Technology for Sheet Metal, J. Mater. Process. Technol., Vol. 129, No. 1-3, pp. 333-338. https://doi.org/10.1016/S0924-0136(02)00685-4
  5. D. S. Shim, D. Y. Yang, K. H. Kim, M. S. Han, S. W. Chung, 2009, Numerical and Experimental Investigation into Cold Incremental Rolling of Doubly Curved Plates for Process Design of a New LARS(line array roll set) Rolling Process, CIRP Annals-Manuf. Technol., Vol. 58, No. 1, pp. 239- 242. https://doi.org/10.1016/j.cirp.2009.03.112
  6. S.C. Heo, Y. H. Seo, T. W. Ku, J. Kim, B. S. Kang, 2009, Study on Application of Flexible Die to Sheet Metal Forming Process, Trans. Mater. Process., Vol. 18, No. 7, pp. 556-564. https://doi.org/10.5228/KSPP.2009.18.7.556
  7. S. C. Heo, Y. H. Seo, B. S. Kang, J. Kim, 2012, Numerical and Experimental Study for Improvement of Formability in Flexible Forming Process, Trans. Mater. Process., Vol. 21, No. 7, pp. 433-440. https://doi.org/10.5228/KSTP.2012.21.7.432
  8. Y. H. Seo, B. S. Kang, J. Kim, 2012, Compensation for Elastic Recovery in a Flexible Forming Process Using Predictive Models for Shape Error, Trans. Mater. Process., Vol. 21, No. 8, pp. 479-484. https://doi.org/10.5228/KSTP.2012.21.8.479
  9. S. C. Heo, T. W. Ku, W. J. Song, J. Kim, B. S. Kang, 2010, Study on Flexible Forming Process Involving the Use of Sectional Flexible Die for Sheet Material, Trans. Kor. Soc. Mech. Eng., A, Vol. 34, No. 3, pp. 299-305. https://doi.org/10.3795/KSME-A.2010.34.3.299
  10. S. C. Heo, Y. H. Seo, J. W. Park, T. W. Ku, J. Kim, B. S. Kang, 2010, Application of Flexible Forming Process to Hull Structure Forming, J. Mech. Sci. Technol., Vol. 24, No. 1, pp. 137-140. https://doi.org/10.1007/s12206-009-1119-4

Cited by

  1. Effect of Shape Design Variables on Flexibly-Reconfigurable Roll Forming of Multi-curved Sheet Metal vol.23, pp.2, 2014, https://doi.org/10.5228/KSTP.2014.23.2.103
  2. Development of a Flexibly-reconfigurable Roll Forming Apparatus for Curved Surface Forming vol.25, pp.3, 2016, https://doi.org/10.5228/KSTP.2016.25.3.161
  3. Evaluation of Formability Dependent on Reconfigurable Roller Types for 3D Curved Sheet Forming vol.25, pp.1, 2016, https://doi.org/10.5228/KSTP.25.1.12