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Theoretical and experimental analysis of springback compensation for four-roll roll forming

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Abstract

The four-roll bending machine is large-scale bending equipment. It has a wide range of applications in various engineering industries. Rebound is an unavoidable phenomenon in the process of profile roll forming, which directly affects the processing accuracy of the profile. In order to improve the forming quality of four-roll bending machine bending profiles after rebound, the forming process flow is first analyzed, and according to the relationship between its four-roll bending and side roll displacement, the establishment of a mathematical model of the side roll displacement in the state of no rebound; secondly, the Bouhêlier rebound equation is combined with the mathematical equation of side roll displacement to obtain the theoretical forming radius-side roll displacement relationship equation and finite element simulation to verify; then, through the prototype of the actual roll forming, the measured roll forming data through MATLAB processing, through the Power function fitting to get the actual forming radius-side roll displacement relationship and generate functional equations, and with the theoretical forming radius-side roll displacement of the relationship between the equation combined with the final elasticity of the compensation value of the equation; finally, the elastic compensation equation is verified by the prototype machine, and the average error between the actual radius and the expected radius is only 0.65%, which is within the allowable range of profile bending error. The results show that the compensation method meets the requirements of profile roll bending, and compared with the traditional compensation formula, its roll bending accuracy is significantly improved, in line with the expected requirements.

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Liaocheng University, Liaocheng, China

    Shangsheng Jiang, Yigang **g, Haoyuan Liu, Qun Sun & Ying Zhao

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  1. Shangsheng Jiang
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  2. Yigang **g
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  3. Haoyuan Liu
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  4. Qun Sun
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  5. Ying Zhao
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Correspondence to Qun Sun.

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Technical Editor: Diego Carou Porto.

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Appendix

Appendix

1.1 Solve RT

figure a

1.2 Solve β

figure b

1.3 Solve Y

figure c

1.4 Solve3Polynomial

figure d

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Jiang, S., **g, Y., Liu, H. et al. Theoretical and experimental analysis of springback compensation for four-roll roll forming. J Braz. Soc. Mech. Sci. Eng. 46, 446 (2024). https://doi.org/10.1007/s40430-024-05026-2

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