The peak strain (PS) of sheet metal highly affects the process design and the quality of roll formed product. Different from the traditional roll forming technology (RFT) that all the cross section contours of the product are rolled simultaneously, a symmetric RFT is developed with respect to the corrugated channels under the study to avoid defects like tearing, twist and redundant deformations. The behaviors of their peak strains are subsequently simulated with Finite Element (FE), and the effects of three factors of the rolling speed, friction coe cient and the bending angle of roll are analyzed, respectively. Finally, both the rationality of RFT and the accuracy of nal rolled product are veri ed by experiments. Results show that for two roll forming channels at the same time, even under the equal bending angles and the pressures of rolls, their maximum peak strains are also distinguished for their different channel widths. The maximum PS of the narrow channel is signi cantly larger than that of the wide, and the closer to the middle channel, the greater the PS of the narrow channel, which is on the right of bending angle of the trough. Moreover, the maximum PS is dominant by the friction coe cient and bending angle of the rst forming pass. This can provide a reference in the design of RFT and improving the quality of the nal rolled corrugated channels.
Central pose errors involving central position error and central orientation error are critical indexes for 6-degrees of freedom docking mechanism assembly quality. The performance of assembly could be evaluated during virtual assembly stage in terms of these indexes. However, the evaluation process for assembly has to employ Monte Carlo simulation, which leads to huge computation cost and usually makes the process impossible. This paper gives an insight of the relation between central pose errors and structural errors and finds that the central position error and central orientation error of docking mechanism conform to Rayleigh distribution model at symmetric pose configuration. In comparison, the maximum difference between results with Rayleigh model-based assembly performance and Monte Carlo simulation-based one is no more than 1.22%. With this model, the evaluation process for assembly performance could be facilitated significantly.
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