Device design and forming process analysis of curved rigid roll rolling process for three-dimensional surface

In order to realize the rapid forming of three-dimensional surface, a new process based on the continuous cold rolling with curved rigid roll is proposed. In this process, the transversal bending deformation of metal plate is caused by the rolls shape; at the same time, it is unevenly thinned by the symmetry uneven roll gap composed by the upper and lower roll; the longitude deformation is caused. With the rolls rotating, the metal plate is continuously formed; the three-dimensional surface is produced. The formation mechanism of three-dimensional surface is stated; the theory and method of three-dimensional surface rolling forming controlling are presented; the longitude bending deformation caused by unevenly thickness thinning is analyzed, and the formula of bending deformation in the longitude direction is deducted, and the calculation method of roll gap and roll contour curve is established. A small test device is developed to form the convex and saddle surfaces, and the forming results are measured and analyzed by numerical simulation. The results indicate that curved rigid roll rolling process is feasible and effective for forming three-dimensional surface.