基于弯曲辊轧制的曲面零件连续成形机理及关键技术基础研究

Rolling process for the continuous forming of three-dimensional surface based on bended roll is a new sheet metal forming technology which is created to solve the problem of manufacturing large curved surface rapidly, effectively and with lower-cost. In this project, rolling technique which is usually used in bulk forming is applied to sheet metal forming and a new way to shape three-dimensional surface parts is proposed. By controlling the gap distribution between two forming rolls in the rolling process using bended roll, the sheet metal is nonuniformly thinned while bent in transversal direction, which leads to bending deformation in longitudinal direction, and a curved surface part is continuously formed with the rotations of the forming rolls. Based on the theoretical, experimental and numerical simulation investigations, this project will explore the new principle and new technique of curved surface rolling, expound the law of sheet metal deformation, reveal the mechanism of curved surface formation, present the theory and method for controlling the formed surface shape and set up a system theory of curved surface rolling; On the basis of the study on the creative structures for shape-adjusting, controlling and driving of bended roll, the project will solve the key technological problems on the curved surface rolling setup, and develop an experimental setup. A series of curved surface rolling tests for typical surface parts will be carried out to demonstrate the validity and feasibility of the presented process.

基于弯曲辊轧制的曲面连续成形是为解决大型三维曲面零件的快速、高效、低成本加工问题而创建的板料成形新技术。本项目将用于体积成形的轧制技术用于板料成形，形成加工三维曲面的新思路。在弯曲辊轧制过程中, 通过控制上下成形辊的辊缝分布，使板料在横向弯曲变形的同时厚向不均匀减薄，导致纵向弯曲变形，从而随着成形辊的转动连续成形出曲面零件。本项目将通过系统的理论、实验与数值模拟研究，探讨曲面轧制成形的新原理与新工艺，阐明板料的变形规律与曲面的形成规律，揭示曲面形成机制，建立成形曲面形状控制方法，形成曲面轧制成形的基本理论；研究用于可弯成形辊调形、控制及驱动的创新机构，解决成形装置开发方面的关键技术问题，研制出曲面轧制成形实验装置，进行典型曲面件的系统成形实验，成形出多种三维曲面，证明曲面连续轧制成形技术的有效性与可行性。

基于弯曲辊轧制的曲面连续成形是为解决大型三维曲面零件的快速、高效、低成本加工问题而创建的板料成形新技术。本项目将用于体积成形的轧制技术用于板料成形，以轴线可弯曲的小直径辊作为成形工具，通过与轧制成形方式相结合，形成加工三维曲面的新思路。在弯曲辊轧制过程中, 通过控制上、下成形辊的辊缝分布，使板料在横向弯曲变形的同时厚向不均匀减薄，导致纵向弯曲变形，从而随着成形辊的转动连续成形出曲面零件。本项目通过系统的理论、实验与数值模拟研究，对曲面轧制成形的新原理与新工艺进行了研究，阐明了板料的变形规律与曲面的形成规律，揭示了曲面形成机制，建立了控制成形曲面形状的方法，形成了曲面轧制成形的基本理论；基于对可弯成形辊调形机构、控制机构及驱动机构的创新研究，解决了成形装置开发方面的关键技术问题，研制出曲面轧制成形实验装置，并开发出用于成形过程控制的软件系统，进行了典型曲面件的系统成形实验，成形出多种三维曲面，证明了曲面连续轧制成形技术的有效性与可行性。本项目的成果解决了曲面轧制成形理论与成形过程控制等关键问题，为该技术的工程应用奠定了基础。曲面轧制成形方法由于其高柔性、低成本，非常适用于大型曲面零件的生产，该技术成熟后有望改变传统的曲面件成形方式，具有非常广阔的应用前景。