柔性辊压成形技术及装备发展现状与展望*

doi:10.16731/j.cnki.1671-3133.2024.01.022

摘要/Abstract

摘要： 柔性辊压成形是一种新型塑性加工技术,与传统带材成形技术相比,该工艺通过多道次成形辊小角度变化完成成形要求,结合了自动化及高水平智能控制系统,工艺先进性高,该工艺的升级可以更好地利用框架式结构来实现轻量化。针对成形构件的不同特征,包括等截面、变截面、轴线侧弯和变深度构件,调研了辊压成形工艺的研究现状,包括机理机制、成形受力及有限元仿真。描述了该工艺成形过程中出现的缺陷类型及产生机理,给出了控制各类缺陷所使用的改进措施。最后总结了该工艺目前已应用的领域和未来重点开发应用的领域,指出该工艺在采用高自动化水平制造高精度、高质量构件方面具有良好的发展前景。

关键词: 辊压成形, 柔性, 型材, 轻量化, 缺陷

Abstract: Flexible roll forming is a new plastic processing technology,compared with the traditional strip forming technology,the process takes the multi-pass forming roll small angle changes to complete the forming requirements,combined with automation and high-level intelligent control system,high technology advanced,the upgrade of the process can better use the frame structure to achieve lightweight. According to the different characteristics of forming members,including equal section,variable section,axis side bending and variable depth members,the research status of roll forming technology was investigated,including the mechanism,forming force and finite element simulation. The types and mechanisms of defects in the process of forming were described,and the improvement measures used to control these defects were given. Finally,the application fields of this process and the key development and application fields in the future were summarized.It was pointed out that this process has a good development prospect in manufacturing high-precision and high-quality components with high automation level.

Key words: roll forming, flexible, profiles, light weight, defect

中图分类号:

TG306

郭文凤, 刘春梅, 王云, 郑硕, 冯宇程. 柔性辊压成形技术及装备发展现状与展望^*[J]. 现代制造工程, 2024, 520(1): 151-161.

GUO Wenfeng, LIU Chunmei, WANG Yun, ZHENG Shuo, FENG Yucheng. Development status and prospect of flexible roll forming technology and equipment[J]. Modern Manufacturing Engineering, 2024, 520(1): 151-161.

参考文献

[1] 李玉杨.长桁类零件弯曲成型技术的研究[D].哈尔滨:哈尔滨工业大学,2015.
[2] 韩非,石磊,肖华.应用先进高强钢的典型汽车零件辊压成形关键技术及开发[J].塑性工程学报,2013,20(3):65-69.
[3] 胡裕祺,郭雪艳,徐晓东.轨道车辆铝型材结构件成形的装置设计[J].机车车辆工艺,2020(4):35-37.
[4] 孙勇,吴本钊,张东星.辊冲复合成形研究现状[J].塑性工程学报,2022,29(11):67-84.
[5] SEDLMAIER A,DIETL T.3D roll forming center for automotive applications[C]//17th International Conference on Metal Forming.[S.l.]:Elsevier B.V.,2018.
[6] TRAUB T,CHEN X,GROCHE P.Experimental and numerical investigation of the bending zone in roll forming[J].International Journal of Mechanical Sciences,2017(7):956-970.
[7] 小奈弘,刘继英.冷弯成型技术[M].北京:化学工业出版社,2008.
[8] LIU S,XIA Y.Tool path planning of consecutive free-form sheet metal stamping with deep learning[J].Journal of Materials Processing Tech,2022,303:117350.
[9] PEREIRA M P,ROLFE B F.Temperature conditions during ′cold′ sheet metal stamping[J].Journal of Materials Processing Technology,2014(214):1749-1758.
[10] BUETTNER R,BILO M,BAY N,et al.A systematic literature review of medical image analysis using deep learning[C]//2020 IEEE Symposium on Industrial Electronics & Applications (ISIEA).[S.l.]:IEEE,2020.
[11] CHEN P J,WU TL,LIN T J,et al.Life Period estimation of stamping process using punch sounds and deep neural network[C]//2019 14th IEEE Conference on Industrial Electronic and Applications(ICICA).[S.l.]:IEEE,2019.
[12] ENOMOTO K,SAKURADA K,WANG K,et al.Filmy cloud removal on satellite imagery with multispectral conditional generative adversarial nets[C]//2017 IEEE Conference on Computer Vision and Pattern Recognition Workshops (CVPRW).[S.l.]:IEEE,2017.
[13] LIU S,SHI Z,LIN J.Reinforcement learning in free-form stamping of sheet-metals[C]//18th International Conference Metal Forming 2020,Procedia Manufacturing.[S.l.]:[s.n.],2020.
[14] GUO J,LI W,WAN M.Design of an innovative laser-assisted four-point bending forming process for high-stiffened structure of aluminum alloy[J].Optics and Laser Technology,2021,143:107313.
[15] LU F,LI Y,HUANG X.An investigation of creep age forming of AA7B04 stiffened plates:experiment and FE modelling[J].Journal of Manufacturing Processes,2019(37):232-241.
[16] YANG Y,ZHAN L.Forming characteristics of AA2219 integrally-stiffened plate subjected to creep age forming[C]//17th International Conference on Metal Forming,2018,Procedia Manufacturing.[S.l.]:[s.n.],2018.
[17] LIU Y,SONG L,YIN J,et al.Numerical Simulation of Stretch Bending for L-section Aluminum Alloy profile[J].Electronic Journal of Structural Engineering,2018,18(2):67-75.
[18] FU Z M,MO I H,GONG P.Mould correction for sheet metal multi-step incremental air-bending forming based on close-loop control and FEM simulation[J].International Journal of Mechanical Sciences,2009,51(2):732-740.
[19] FU Z M,MO J H,ZHANG W X.Study on multiple-step incremental air-bending forming of sheet metal with springback model and FEM simulation[J].International Journal of Advanced Manufacturing Technology,2009,45(5):448-458.
[20] FU Z M,MO J H,CHEN L.Using genetic algorithm-back propagation neural network prediction and finite-clement model simulation to optimize the process of multiple-step incremental air-bending forming of sheet metal[J].Materials and Design,2010,31:267-277.
[21] WANG A,XUE H.Improvement of springback prediction accuracy for Z-section profiles in four-roll bending process considering neutral layer shift[J].Journal of Manufacturing Processes,2019(48):218-227.
[22] 王英爽.三维辊压成形有限元建模及工艺分析[D].北京:北方工业大学,2014.
[23] BADR O M,ROLFE B,HODGSON P.Forming of high strength titanium sheet at room temperature[J].Materials and Design,2015,66(3):618-626.
[24] BADR O M,ROLFE B,WEISS M.Effect of the forming method on part shape quality in cold roll forming high strength Ti-6Al-4V sheet[J].Journal of Manufacturing Processes,2018,32(3):513-521.
[25] BADR O M,ROLFE B,ZHANG P.Applying a new constitutive model to analyse the springback behaviour of titanium in bending and roll forming[J].International Journal of Mechanical Sciences,2017,128(5):389-400.
[26] LARRANAGA J,GALDOS L,L.Development and validation of a numerical model for sheet metal roll forming[C]//Int J Mater Form.[S.l.]:Springer-Verlag,2010.
[27] TRAUB T,CHEN X,GROCHE P.Experimental and numerical investigation of the bending zone in roll forming[J].International Journal of Mechanical Sciences,2017,131(7):956-970.
[28] MONEKE M,GROCHE P.End flare of profiles with multiple bending zones[J].Procedia Manufacturing,2018,15(7):743-750.
[29] BIDABADI B S,NAEINI H M,TAFTI R A.Experimental and numerical study of required torque in the cold roll forming of symmetrical channel sections[J].Journal of Manufacturing Processes,2017,27(4):63-75.
[30] TEHRANI M S,HARTLEY P,NAEINI H M.Localised edge buckling in cold roll-forming of symmetric channel section[J].Thin-Walled Structures,2006,177(1):617-620.
[31] 邹仲平.不锈钢波纹板辊型设计及冷弯成形规律研究[D].长春:吉林大学,2007.
[32] LIU H,LI S,CAO J.Simulation Research on Roll Forming in Container Roof[C]//2021 International Conference on Advances in Optics and Computational Sciences.[S.l.]:IOP Publishing Ltd.,2021.
[33] 廖彦文.轿车纵梁加强板混压成形关键技术研究[D].长春:吉林大学,2016.
[34] 李健东.商用车防撞梁辊弯及绕弯精密成形技术研究[D].长春:吉林大学,2021.
[35] JIAO J,ROLFE B,MENDIGUREN J.An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width[J].International Journal of Mechanical Sciences,2014,90(11):228-238.
[36] GROCHE P,ZETTLER A,BERNER S.Development and verification of a one-step-model for the design of flexible roll formed parts[J].Int J Mater,2011,4(4):371-377.
[37] SUN W T,LI Q,QIAN B.Control Strategy for the Flexible Roll Forming Machine with the Structure of Double Rack and Single Gear[C]//2011 International Conference on Transportation,Mechanical,and Electrical Engineering.[S.l.]:North China University of Technology,2011.
[38] SUN W T,LI Q,QIAN B.Track Simulation of Flexible Roll Forming Based on VC++ and OpenGL[J].Advanced Materials Research,2012,457:304-307.
[39] YAN Y,WANG H B,LI Q.Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification[J].Chinese Journal of Mechanical Engineering,2016,29(2):342-350.
[40] YAN Y,WANG H B,LI Q.Simulation and experimental verification of flexible roll forming of steel sheets[J].Int J Adv Manuf Technol,2014,72(1):209-220.
[41] HU Y,LI Q,GUAN Y.The measurement and analysis system development of 3D roll forming machine dynamic characteristics based on virtual instrument[J].Advanced Materials Research,2014(889):726-731.
[42] WOO Y Y,HAN S W,HWANG T W.Characterization of the longitudinal bow during flexible roll forming of steel sheets[J].Journal of Materials Processing Technology,2018,252(10):782-794.
[43] YANG Z F,LI Q,GUAN Y Z.Dynamic Analysis of 3D Roll Forming Equipment in Mechanical System[J].Advanced Materials Research,2013,740:323-331.
[44] KASAEI M,NAEINI H M,LIAGHAT G.Revisiting the wrinkling limits in flexible roll forming[J].Journal of Strain Analysis,2015,50(7):528-541.
[45] KASAEI M M,NAEINI H M,ABBASZADEH B.Flange wrinkling in flexible roll forming process[C]//11th International Conference on Technology of Plasticity.[S.l.]:Procedia Engineering,2014.
[46] ABEYRATHNA B,GHANEI S,ROLFE B.Optimising part quality in the flexible roll forming of an automotive component[J].The International Journal of Advanced Manufacturing Technology,2022,118(9):3361-3373.
[47] ABEYRATHNA B,GHANEI S,ROLFE B.Springback and end flare compensation in flexible roll forming[C]//IOP Conference Series Materials Science and Engineering.[S.l.]:[s.n.],2020.
[48] ABEYRATHNA B,ABVABI A,ROLFE B.Numerical analysis of the flexible roll forming of an automotive component from high strength steel[C]//IDDRG2016 conference on "Challenges in Forming High-Strength sheets".[S.l.]:IOP Publishing,2016.
[49] KIM D,CHA M,KANG Y S.Development of the Bus Frame by Flexible Roll Forming[C]//17th International Conference on Sheet Metal.[S.l.]:Procedia Engineering,2017.
[50] SEDLMAIER A,DIETL T,FERREIRA P.Digitalization in roll forming manufacturing[C]//36th IDDRG Conference-Materials Modelling and Testing for Sheet Metal Forming.[S.l.]:IOP Publishing,2017.
[51] YAN Y,NIE H,WANG H.A novel roll-die forming technology and its FEM simulation[C]//International Conference on the Technology of Plasticity.[S.l.]:Procedia Engineering,2017.
[52] WOO Y,KANG P.Flexible roll forming of double layered blank[C]//17th International Conference on Metal Forming.[S.l.]:Procedia Manufacturing,2018.
[53] ABEYRATHNA B,ROLFE B,HARRASSER J.Prototyping of automotive components with variable width and depth[C]//36th IDDRG Conference-Materials Modelling and Testing for Sheet Metal Forming.[S.l.]:IOP Publish-ing,2017.
[54] WANG T,GROCHE P.An analytical model for designing defect-free sheet metal profiles with height-variable cross sections manufactured by Flexible Roller Beading[J].International Journal of Material Forming,2022,15(4):49.
[55] WANG T,GROCHE P.Sheet Metal Profiles with Variable Height:Numerical Analyses on Flexible Roller Beading[J].Manufacturing and Materials Processing,2019,3(1):19.
[56] 王东涛.7055铝合金热成形工艺优化及回弹控制[D].成都:西南交通大学,2021.
[57] 陈庆敏,胡维学,李明哲,等.连续辊压成形中的起皱缺陷分析[J].锻压技术,2016,41(9):52-57.
[58] 陈荷.典型航空产品长桁的加工工艺分析[J].机床与液压,2014,42(22):84-86.
[59] 王双枝,杨谊丽,朱梅云.辊压成形工艺研究及在汽车行业中的应用[J].金属加工,2016(17):10-13.
[60] 杨雪,王海玲,刘程,等.汽车窗框辊压工艺及设备浅析[C]//金属加工热加工.合肥:安徽江淮汽车股份有限公司技术中心,2016.
[61] 孔凡燕,崔礼春,虞帅,等.辊压技术在汽车门槛成形中的研究与应用[J].锻压装备与制造技术,2019,54(6):94-96.
[62] 闵范磊,岳博文,高绪杰.汽车天窗导轨悬臂型材挤压模具设计及工艺参数优化[J].现代制造工程,2019(9):76-80.
[63] 郑帮智.汽车梁辊压成形的数值模拟[J].锻压技术,2019,44(10):94-100.
[64] 胡裕祺,郭雪艳,徐晓东.轨道车辆铝型材结构件成形的装置设计[C]//工装设备.烟台:山东诺维科轻量化装备有限公司,2020.

柔性辊压成形技术及装备发展现状与展望^*

Development status and prospect of flexible roll forming technology and equipment

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

[1]	曹节强, 李军利, 刘钢, 张立强. 基于形态学的自动铺丝纤维铺放准确性检测^*[J]. 现代制造工程, 2024, 524(5): 15-22.
[2]	张殷晨, 左鹏奇, 王逸飞, 林楠, 谢润, 金立军. 基于遗传算法的家电智能生产线分布式资源调度算法设计^*[J]. 现代制造工程, 2024, 524(5): 31-38.
[3]	马涛, 李敬兆. 基于MFA-UNet的铜制螺纹零件外表面缺陷检测^*[J]. 现代制造工程, 2024, 524(5): 113-120.
[4]	高山凤, 雷乐, 赵伦, 叶凯, 李承旺, 赵升升, 宋振东, 鲍丹阳. 航空铝钛合金自冲铆接成形机理及力学行为研究^*[J]. 现代制造工程, 2024, 523(4): 1-6.
[5]	黎增灿, 丁林山, 管在林. 基于改进灰狼优化算法的柔性作业车间分批调度问题研究[J]. 现代制造工程, 2024, 523(4): 13-25.
[6]	孙鸿羽, 吉卫喜, 李威, 刘凯. 基于海鸥优化算法的分布式柔性车间调度研究[J]. 现代制造工程, 2024, 523(4): 33-42.
[7]	曾飞, 李斌, 周健, 樊江峰. 改进YOLOv7算法的排水管道缺陷检测与几何表征[J]. 现代制造工程, 2024, 522(3): 110-118.
[8]	许建龙, 薛瑞雷, 吴立斌, 李晓娟, 刘宏胜. 窄间隙GMAW咬边缺陷的电弧声信号特征分析与识别^*[J]. 现代制造工程, 2024, 521(2): 137-141.
[9]	刘智飞, 李国林. 不确定条件下基于区间灰数的柔性车间调度^*[J]. 现代制造工程, 2024, 520(1): 17-23.
[10]	闫富乾, 石致远, 王立闻. 基于改进灰狼算法的柔性作业车间动态节能分批调度问题^*[J]. 现代制造工程, 2024, 520(1): 24-32.
[11]	孔云, 周学良, 冷杰武. 基于改进白鲸优化算法的低碳柔性工艺规划^*[J]. 现代制造工程, 2024, 520(1): 80-88.
[12]	陶昊;王艳;纪志成. 多工艺路线下柔性加工系统Petri网调度方法[J]. 现代制造工程, 2023, 516(9): 9-17.
[13]	李峥峰;丁其聪;张东方;张国辉. 改进离散麻雀搜索算法求解柔性作业车间调度问题[J]. 现代制造工程, 2023, 516(9): 18-27.
[14]	高齐;尹明锋;吴祥;符诗语;贝绍轶. 融合多尺度-注意力机制和迁移学习的齿轮表面缺陷识别方法[J]. 现代制造工程, 2023, 515(8): 7-14.
[15]	陆心屹;韩晓龙. 基于强化学习的改进NSGA-Ⅱ求解柔性作业车间节能调度问题[J]. 现代制造工程, 2023, 515(8): 22-35.