Study On Roll Forming Grooves On The Surface Of Sheet Metal

Micro-grooves on the surface of the plate is a typical microstructure of the surface, it has special functions such as drag reduction, super hydrophobic, wear resistance and so on, which makes it show a broad application prospects in the aviation navigation, new energy, micro mechanical electronics, and many other areas. Micro-groove roll forming technology on the sheet metal surface is a kind of highly efficient and low-cost micro-groove forming method, and can realize the high-throughput fabrication of micro-grooves structures on the surface of sheet metal. In this paper, a roll-to-roll(R To R) forming process was proposed for efficiently and economically fabricating micro-grooves on the surface of the thin sheet metal. The finite element model was established by ABAQUS and numerical analysis of the forming process of surface grooves was under different technological conditions. The rolling forming device with a flexible supporting roller was developed, the reliability of the structure was analyzed, and the rolling experiment was carried out. The main research contents of this paper are as follows:(1) This paper analyzed the deformation theory of roll forming, explained the theory of the bite, forward slip and bending of the sheet metal, and provided the calculation method of the rolling force.(2) The numerical simulation of roll forming for sheet metal with different widths was conducted, the transverse deformation of the plate during rolling process was analyzed using the inductive method. The numerical simulation of the plate with different temperature was carried out. It is concluded that the maximum stress value was small and the rolling force decreased at high temperature. At the same time, the deformation of the groove was increased. So it is reasonable to control the forming temperature of sheet metal, which is advantageous to the micro-groove forming.(3) The finite element model with different groove spacing was established. Under different conditions,the forming depth of the groove was analyzed, and the variation law of the sheet thinning quantity was analyzed. The curvature radius of sheet metal got through nonlinear fitting of the middle node connection in the longitudinal direction of the forming part by the circular arc curve formula, the curvature radius was used as the evaluation method of the bending degree of the plate. The bending deformation of the forming parts with different groove spacing was analyzed. The influence of the process parameters on the forming depth of the grooves, the thickness of the plate and the longitudinal bending of the plate were analyzed by comparing the difference of the roll gap, the thickness and the roll diameter. Through the analysis of plate micro grooves on the surface of asynchronous forming process, the results showed that reasonable controlling and different speed can increase the surface plate groove forming depth, decrease the longitudinal bending of plate and reduce rolling force.(4) A rolling forming device with a flexible supporting roller was developed.The reliability of the equipment was verified by numerical simulation. Rolling experiment was conducted on the plates with different widths and thickness, according to the experimental results, the deformation law of the plate was analyzed. The rolling forming experiments under different pressure conditions were conducted to analysis the relationship between the downforward displacement with the bending of the plate and the depth of the grooves.