Transverse bending deformation analysis of 3D surface part in continuous roll forming process

This paper introduces a newly developed technique called continuous roll forming process which is applied to manufacture 3D surface part with various shapes, especially for doubly curved parts. In continuous roll forming process, the twin bendable rolls are placed to form a nonuniform roll gap. The bendable rolls rotate in opposite directions around the bend axis with equal angular velocity. The sheet metal is bitten into the roll gap by friction force and compressed nonuniformly across its width. At the present, how to precisely predict transverse bending deformation of 3D surface part has become a critical issue for guiding practical forming in the continuous roll forming process. This work focuses on analysis of the transverse bending deformation characteristics in continuous roll forming process.