Single-axle Roll-bending Research And Finite Element Analysis Of The U-profile

Single-Axle Bending Technique with Elastic Rubber(SABTER) is an advanced and highly flexible manufacturing technology for sheet metal forming. Compared with the traditional bending method, the products of bending have the advantages of high strength, good surface quality and low cost. It is especially suitable to aerospace and automobile industries with single or mini-batch production.In this study, the principle of the technique is discussed comprehensively. The main work and results in this dissertation can be concluded as follows:1,According to the principle of the SABTER, a U-profile roll bending device which is based on NC incremental forming machine tools is designed. The experimental research indicates that SABTER has a critical feed .The radius of curvature is no longer changed with the feed increasing when the feed exceed the critical feed. A limit radius that is proportional to the diameter of the rigid roller may be obtained.2,Based on the force analysis of the SABTER and a series of simplifying for the stress and deformation of the workpiece, a theoretical mould that describes the flexible roll bending the U-profile is proposed by the description of elastic-plastic theory.With this theoretical mould, the formula about the curvature radius of the workpiece and the major influencing factors have been found.3,In finite element analysis, the mechanical property of rubber material is always described by strain energy function. In this paper, some commonly used strain energy functions of the rubber are described. The"Mooney-Rivilin"material model is used in FEA. Data of Uniaxial tension and compression tests are inputted into Msc.marc software package to compute the two parameters of Mooney-Rivilin material model.4,The FEA model of the flexible roll bending U-profile has been built with the FEA software Msc.marc. The loading and Springback process have been simulated. With the results of FEA, major factors related to springback have been analyzed and the important feature of SABTER from experiment has been verified. Compared with the experimental results, it shows that the simulation has a good precision and the FEA mode has a certain practical application value.