Analysis on the wrinkling in continuous roll forming of three-dimensional surface parts

Continuous roll forming is a new sheet metal forming process for three-dimensional surface parts.In the process, the sheet metal is thinned non-uniformly in transverse direction by controlling the distribution of the gap between the upper and lower forming rolls, the longitudinal elongation is different, which makes the sheet metal generate a doubly curved surface parts.When sheet metal forming, the complex stress state produced in the sheet.Since the size in thickness is much smaller than in the transverse and longitudinal directions, the energy required for the deformation of the thin plate is small, it is easy to produce wrinkling problems.In this paper, finite element analysis model is established, wrinkling in the spherical surface and saddle surface are simulation and the experimental results of the wrinkling in saddle surface is presented.The results demonstrate that unreasonable distribution of the roll gap is the main reason for the generation of wave-shaped wrinkling.