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The
present work presents basically mathematical modelling of bending of sheet
metal using roll forming process. In this analysis it is assumed that the
elastic-plastic region during the rolling process varies in sinuous form
which was approximated by a constant variation.
The theory predicts a number of factors which are normally
important to the bending operation, such as roll separating force,
spring-back and horse power. These parameters are functions of mechanical
properties and geometry of the materials, friction and geometry of the rolls
and also the types of the roll machine. It was found that the friction
condition and the anisotropy of the metal played na important part in
predicting the theoretical values. This will be discussed in detail in the
text.
Experiments
were also performed on various materials having different work hardening
conditions, such as stainless steel, copper and aluminium alloys.
Comparisons between the predicted value from the present theory and the
experimental results of roll bending using three rolls were found to be in
good agreement.
Other relevant
parameters to this process were also examined.
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