Research on rolling process of bow parts with variable lateral roll spacing based on optimal bending angle distribution function

For roll-bending formation in bow-shaped sheet metal parts, the distance of the traditional roll-forming transverse unit is constant, which often causes corner wrinkles, corner cracks, tearing, springback, and peak longitudinal strain defects throughout the formation process. To solve these shortcomings, this paper proposes an optimized bending angle distribution function to synergize the variable lateral roll distance technique. By parameterizing the abstract function according to the function boundary trajectory, the bending angle of each roll pass is measured; furthermore, the optimal function curve can be obtained through finite element analysis. Then, the roll-bending simulation is conducted, and the forming angle of the sheet metal parts is redistributed to determine the most effective reduction of peak longitudinal strain and transverse roll spacing. The bending angle distribution function aids the variable transverse roll distance technology to execute roll-bending experiments on 3004Al arch parts, ultimately obtaining the optimal roll-bending angle and transverse roll distance. The results of the roll forming simulation, based on the optimized bending angle distribution function and variable transverse roll distance technology, corroborate the experimental results, and good roll forming efficiency and quality are achieved.