Modeling of Deformation Zone during Plate Stock Molding in Three-Roll Plate Bending Machine

Zhigulev, G. P.; Skripalenk, M. N.; Fadeev, V. A.; Skripalenko, M. M.

doi:10.1007/s11015-020-01002-y

Cited by 7 publications

(2 citation statements)

References 12 publications

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“…Known solutions [15,16] which define regimes of tube billet forming when using 3-roller bending mills mostly consider deformation zone structure as symmetrical with application of load to bending roller in the middle of its contact surface and with bearing of billet on lower bearing rollers. However, latest research [17][18][19][20] has demonstrated the following. When upper bending roller is replaced without rotation, four-point contact symmetrical deformation zone is formed and separation of billet from the surface of the bending roller.…”

Section: Introductionmentioning

confidence: 99%

Modelling of the sheet forming while 3-roller bending process

Zhigulev¹,

Skripalenko²,

Fadeev³

et al. 2022

cisisr

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3-roller bending process was investigated using physical modelling and computer simulation. Main technological parameters influence on the formation of tube billet diameter are present; these main technological parameters are upper roller displacement and distance between axes of bearing rollers. Complete factorial experiment was conducted using bending machine, radius of the produced tube billet was set as response function. Conditions for conducting the complete factorial experiment using bending machine and techniques of tube billet radius estimation by graphical-analytical method are presented. At that least square method and SolidWorks software were applied. Regression equations for calculating tube billet diameter conditionally upper roller displacement and distance between axes of bearing rollers were obtained. Influence of these two factors on tube billet radius formation was demonstrated. Finite element method (FEM) computer simulation of the forming process was done with respect to parameters corresponding to parameters of physical modelling experiment using bending machine. FEM computer simulation was done using QForm software. QForm simulation was realized for elastic-plastic bending in terms of two-dimensional deformation. Point tracking was applied to calculate coordinates of the points of the formed sheet and bending parameters. It allowed estimation of the neutral line location in the formed sheet when bending stage was finished. Presented results of computer simulation are figures with trajectories of the tracked points; figures illustrating changing of distance between tracked points; graph of accumulated strain changing through sheet's thickness. New criterion for neutral line (neutral surface) was proposed for sheet bending process. Results of the research can be effective when exploring Heausler AG bending equipment.

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Section: Introductionmentioning

confidence: 99%

Modelling of the sheet forming while 3-roller bending process

Zhigulev¹,

Skripalenko²,

Fadeev³

et al. 2022

cisisr

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“…In the literature, many outstanding theoretical and experimental researches [2,[8][9][10][11][12][13] have been performed to develop analytical and empirical models as well as FEA models regarding three-roller and four-roller machines. Gandhi and Raval [2] discussed three analytical concepts for pyramid type three-roller bending process and proposed an empirical model to estimate the top roller position explicitly as a function of desired (final) radius of curvature for three-roller bending considering the contact point shift at the bottom roller plate interfaces.…”

Section: Introductionmentioning

confidence: 99%

Explicit dynamics finite element analyses of asymmetrical roll bending process

Kamas¹,

SARIKAYA²

2021

International Advanced Researches and Engineering Journal

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In this article, results obtained from a preliminary study that contains a set of explicit dynamics finite element analyses of a metal plate bending process are presented through 3D asymmetrical three roller models. ANSYS Ls-Dyna explicit dynamics finite element (ED-FEA) preprocessor and solver were used to carry out dynamic simulations. Explicit dynamics of a low-velocity process such as the roll-bending of a metal plate is a computationally expensive method. Since plastic deformation occurs on the plate in addition to elastic flexure to eventually possess a circular geometry, the plate material is considered a non-linear material. In this particular study, an aluminum plate was modeled with the Bilinear Kinematic Hardening model including plasticity parameters such as the tangent modulus. A very significant parameter called the mass scaling factor was taken into account to be able to define a specific time-step that was used to determine the computation time interval and the total temporal cost. However, exaggerated reduction of the computation time results in unphysical consequences. The results were presented before and after redesigning the lower and side rolls having a convex geometry and the peripheral velocity of upper roll rotation was decreased to minimize the distortion that occurred on the pre-bent side walls of the aluminum plate.

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