Abstract: Conical sections and shells of metal plates manufactured by 3-roller conical bending process are widely used in the industries. The process is completed by first bending the metal plates statically and then dynamic roller bending sequentially. It is required to have an analytical model to get maximum bending force, for optimum design of the machine, for static bending stage. Analytical models assuming various stress conditions are considered and these analytical models are compared considering various parameters and reported in this paper. It is concluded from the study that for higher bottom roller inclination, the shear stress affects greatly to the static bending force whereas for lower bottom roller inclination it can be neglected.
Abstract: The paper gives basic information on application of
rotation bending for manufacturing ship hull parts from steel plates
and on MGPS machines, employed for this purpose.
Abstract: Conical sections and shells made from metal plates are widely used in various industrial applications. 3-roller conical bending process is preferably used to produce such conical sections and shells. Bending mechanics involved in the process is complex and little work is done in this area. In the present paper an analytical model is developed to predict bending force which will be acting during 3-roller conical bending process. To verify the developed model, conical bending experiments are performed. Analytical results and experimental results were compared. Force predicted by analytical model is in close proximity of the experimental results. The error in the prediction is ±10%. Hence the model gives quite satisfactory results. Present model is also compared with the previously published bending force prediction model and it is found that the present model gives better results. The developed model can be used to estimate the bending force during 3-roller bending process and can be useful to the designers for designing the 3-roller conical bending machine.
Abstract: Bendability is constrained by maximum top roller
load imparting capacity of the machine. Maximum load is
encountered during the edge pre-bending stage of roller bending.
Capacity of 3-roller plate bending machine is specified by
maximum thickness and minimum shell diameter combinations that
can be pre-bend for given plate material of maximum width.
Commercially available plate width or width of the plate that can be
accommodated on machine decides the maximum rolling width.
Original equipment manufacturers (OEM) provide the machine
capacity chart based on reference material considering perfectly
plastic material model. Reported work shows the bendability analysis
of heavy duty 3-roller plate bending machine. The input variables for
the industry are plate thickness, shell diameter and material property
parameters, as it is fixed by the design. Analytical models of
equivalent thickness, equivalent width and maximum width based on
power law material model were derived to study the bendability.
Equation of maximum width provides bendability for designed
configuration i.e. material property, shell diameter and thickness
combinations within the machine limitations. Equivalent thicknesses
based on perfectly plastic and power law material model were
compared for four different materials grades of C-Mn steel in order
to predict the bend-ability. Effect of top roller offset on the
bendability at maximum top roller load imparting capacity is
reported.