Linear Distribution Principle for Sheet Forming Using Continuous Roll Forming Process

Continuous roll forming (CRF) process utilizes two reconfigurable rollers as forming tools to manufacture 3D surface part. In order to investigate the longitudinal deformation of 3D curved surface part, the detailed mathematical methodology using a geometrical relationship is analyzed and described. The results show that the necessary condition for generating longitudinal bending deformation is the linear distribution of the longitudinal fiber. The deformation characteristics of CRF studied by simulation confirm that the ideal longitudinal deformation is generated when the distribution of longitudinal fibers satisfy the linear distribution principle, the maximum length difference of longitudinal fibers is the major factor determining the longitudinal curvature radius of formed part, and increasing maximum length difference of longitudinal fibers incurs an increasing longitudinal curvature. In addition, 3D surface parts with different longitudinal curvature were prepared by CRF process, which had verified the proposed linear distribution principle.