SIMULATION OF MULTIPLE PASS THREE ROLLER BENDING
Keywords:
Conical bending, Multiple pass bending, Forces, RadiusAbstract
Three roller bending process is used for the formation of cylindrical and conical shell. Due to bender capacity the required shell dimension cannot be obtained in single pass roller bending. Therefore multiple pass bending is performed. During bending plate is bent to loaded radius. During unloading of plate, the radius of the plate increases due to spring back. Analytical models for estimation of unloaded radius during three roller multiple pass bending process have been reported in literatures. These models are based on the assumptions of constant bend radius to simplify the mathematical formulations. One of the ways to overcome these assumptions is to simulate the process through FEA. In the present work an attempt is made to simulate the multiple pass conical bending in FEA software. The variation in radius of the plate as plate passes through the rollers is noted. The increase in the curvature and the spring back occurring in each pass are seen in the results. The forces are found to increase with each pass during bending operation. The results of final radius were compared with the analytical model available in the literature. Present work may serve as a platform for the research in the estimation of the radius and the forces in multiple pass bending through simulation.
Downloads
References
Gandhi A H (2009), “Prediction of machine setting parameters and roller configuration for continues bending of conical shell on three roller bending machine”, Ph. D. Thesis, S. V. National Institute of Technology, India.
Kagzi S A, Gandhi A H, Raval H K (2012), “Stress analysis of frame structure of three roller bending machine using ANSYS”, Journal of manufacturing engineering, Vol. 7(3), 277-283.
Ming Yang, Susumu Shima (1988), “Simulation of bending type three roller bending process”, International Journal of Mechanical Science, Vol. 30(12), 877-886.
Raval H K (2002), "Experimental and theoretical investigation of bending process”, (Vee and three roller bending), Ph. D. Thesis, South Gujarat University, India.
Gandhi A H and Raval H. K. (2008), “Analytical and empirical modeling of top roller position for three roller cylindrical bending of plates and its experimental verification”, Journal of Materials Processing Technology, vol. 197, pp. 268-278, 2008.
Gandhi A H and Raval H K (2009), “Formulation of springback and machine setting parameters for multi-pass three-roller cone frustum bending with change in flexural modulus”, International Journal of Materials Forming, Vol. 2, 45-57.
Chudasama M K and Raval H K (2013), “An Approximate bending force prediction for three roller conical bending process”, International Journal Materials Forming, Vol. 6, 303-314.
Chudasama M K and Raval H K (2014), “Bending force prediction for dynamic roll-bending during 3-roller conical bending process”, Journal of Manufacturing Processes, Vol. 16-2,184-295.
Feng Zhengkun and Chamliaud Henri (2011) , “Modeling and simulation of asymmetrical three-roll bending process”, Simulation Modelling Practice and Theory, Vol. 19, 1913- 1917.
Zeng, Jun, Zhao, heng, Liu and Chamliaud Henri (2008), “FEM dynamic simulation and analysis of roll-bending process for forming of conical tube”, Journal of Materials Processing Technology, Vol. 198, 330-343.
Feng Zhengkun and Chamliaud Henri (2011), “Three stage process for improving roll bending quality”, Simulation Modelling Practice and Theory, Vol. 19, 887-898.
Kagzi S A and Raval H. K. (2014), “An Investigation of forces during roller forming process”, Advanced Materials and Research, Vol. 1036, 337-343.
Kagzi S A and Raval H K (2015), “An Analysis of Forces during Three Roller Bending Process”, International Journal of Materials and Product Technology, Vol. 51(3), 248-263.
Weisstein, Eric W (2016), "Circumradius." From Math World-A Wolfram Web Resource”. http://mathworld.wolfram.com/ Circumradius.html.
