Experimental and numerical analysis of roll bending process of thick metal sheets

Abstract In metalworking, bending forming processes are used extensively for a wide range of applications referring to several industrial fields, such as oil&gas field, naval field or automotive field. cylinders and truncated cones process, three-point roll metal sheets represents concrete option, which mainly consists pyramid-type machines made two lower rolls top roll. Each can be designed work driven an idler move both vertically horizontally during the rolling depending on sheet final product features (mechanical properties, thickness curvature mainly). Final products affected by defects, represent problem metalworking industries because further works done meet customers needs; in bending, warping defect hourglass (or barrel) most common problems. this paper, experimental numerical analysis is proposed detect defects roll-bent thick companies experiences; occurrence variability circumferences along cylinder length considerable differences between internal external themselves, referable so-called ”hourglass defect” major cost companies. A Finite Element (FE) 3D model roll-bending machine simulate mechanical behaviour checking influence spring-back effect moments from rolls. Both pre-bending phases have been simulated. Rolls modelled rigid. using solid elements contact take into account rolls/sheet friction. Obtained results compared with check reliability FE simulation. The itself then implemented central serves placed half-way original ones. updated process again test hourglass-defect solution.