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1、Analytical and empirical modeling of top roller position for three-roller cylindrical bending of plates and its experimental verification The charact type of level eristic of level adjust below three rollers Rolling Machine in thisinvestigation is as follows.Using the adjust,the end can be bendedwit
2、hout turn around and the whole process of plate coiling including entering、center adjusting、pre-bending、coiling、cylinder proofread can be completedcontinuously;due to whole hydraulic pressure driving protocol,the structure wassimplified,and speed and pressure was easily controlled in the process of
3、platecoiling;The setup of the center adjusting and the equip of supporting,the preciseand quality of plate coiling was improved;owing to the simplified structure,theoperation and maintenance is easy to carried out.KeyWord: Bending Machine；the work rolls；mechanical analysis；the transmission system1、R
4、eported research on the forming of cylindrical shells mostly discusses the modeling and analysis of the process. reported the geometrical analysis of the single pass elasto-plastic bending of beams on the three-roller pyramid benders by assuming triangular moment distribution between the rollers. De
5、veloped model for the bending force and bending moment was based on the contact point shift between the plate and top roll from the vertical centerline of the top roll. described closed loop shape control of three-roller bending process. The presented scheme accomplishes the shape control by measuri
6、ng the loaded shape, the loaded moment and effective beam rigidity of the material in real time. discussed the distribution of curvature and bending moment in accordance with the displacement and rotation of the rolls by simulating the deformation of work piece with U-shaped cross-section in a three
7、-roller bending process. They reported the relationship between the bending moment and the curvature of the work piece by elementary method, which was further used to build up a process model combining the geometries for three-roller bending process. 2、Developed process model was further applied to
8、the real time control system to obtained products with constant and continuously varying curvature. reported a process model for use in simulation of the manufacturing of cylindrical shells from the plates, which require sequential bending, by incorporating the prior bend history. They modeled the p
9、rocess with series of overlapping two-dimensional three point bends, where overlap includes the plastic zone from the previous bends. reported the mathematical model for determining the plate internal bending resistance at the top roll contact for the multi-pass four-roll thin plate bending operatio
10、ns along with the principle mechanisms of bending process for single pass and multi-pass bending. have reported a kinematics based symmetric approach to determine the region of the plate to be rolled, in order to form smoothly curved plates. developed the analytical model to estimate the top roller
11、position as a function of desired radius of curvature, for multiple pass three-roller forming of cylinders, considering real material behavior and change of Youngs modulus of elasticity under deformation and shows that the springback is larger than the springback calculated with constant E. Literatu
12、re review reveals that only limited studies are available on the continuous three-roller bending of plates.3、With reported analytical models, it is difficult to find the top roller position explicitly as a function of the desired radius of curvature and hence it requires solving the set of equations
13、 by nonlinear programming. Use of the close loop shape control or adaptive control or CNC control system can improve the accuracy and the consistency of the process but acquisition and maintenance of such a system is costly and may not be affordable to the small scale to medium scale fabricators. Pu
14、rpose of the present analysis is to develop the model for prediction of the top roller position as a function of the desired radius of curvature explicitly for cylindrical shell bending. Development of the model is based on analytical and empirical approach. Empirical model is developed based on the
15、 top roller position versus loaded radius of curvature plots, which is obtained geometrically for a set of data of center distance between bottom rollers and bottom roller radius.4、ConclusionDeveloped analytical and empirical models were verified with the experiments on three-roller cylindrical bend
16、ing. Following important conclusions were derived out of the reported work:(1) Analytical model based on concept 3, simplifies the calculation procedure for the machine-setting parameters as it expresses the top roller position as an explicit function of desired radius of curvature.(2) Agreement of
17、empirical results with that of the experiments and analytical results based on concept 3 proves the correctness of the procedure.(3) For the small to medium scale fabricators, where the volume of production does not permit the acquisition of automated close loop control systems, developed models can
18、 be proved to be simple tool for the first hand estimation of machine setting parameters for required product dimensions.(4) Consideration of effect of initial strain and change of modulus of elasticity during deformation on spring back, in analytical/empirical model will further improve the accurac
19、y of prediction of top roller position.(5) Further, empirical model based on the experimental loaded curvature distribution between roller supports would consider the top roller-plate contact point shift and will lead to more accurate prediction of top roller position.通过实验确认的三辊卷板机上辊位置的分析和经验模型本文研究的水平
20、对称式卷板机特点如下：采用水平下调式，即下辊可作水平移动，可实现不用调头便可预弯端头，使进料、对中、预弯、卷圆、矫圆整个卷板过程连续完成，利于提高生产效率，降低工人劳动强度；设置板料对中装置和支承辊装置，利于提高卷板精度和卷板质量；采用全液压驱动，使设备结构简化，便于卷板过程中的速度和压力控制，起停、换向灵活，运行平稳，操作方便；结构简单，便于操作和维护维修，符合现场技术工人的操作和维修水平，高效实用。关键词：卷板机；工作辊；受力分析；传动系统1、本文是研究形成的圆柱壳的大多是讨论的建模和分析的过程。通过几何分析对三辊对称式卷板机的弹塑性弯曲，假设三角力矩分配之间的轧辊。发展模式的弯曲力和弯矩
21、的基础上，上辊通过在两下辊对称中央作上下移动，而两下辊的左、右旋转。所描述的闭环板形控制的三辊弯曲的过程。由提出的计划，完成板形控制测量加载的形状，加载和有效刚度的材料。 在讨论的分布曲率和弯矩在按照位移和旋转的辊模拟变形的工件与U形截面的过程中和他们之间的关系，弯矩和曲率的工件由初等方法。这是进一步用来建立相结合的几何构型为三辊弯曲的过程。2、对现有的控制系统的产品模型进一步开发，以获得与常数和连续变曲率。模型的使用在模拟制造圆柱壳从板，这就需要连续弯曲，这就得到了事先的弯曲资料。他们用重叠包括来自事先的弯曲的塑料的地域的连续的交叠处理二维的三点弯曲做模型程序了。通过数学模型，确定上辊对板内
22、部弯曲阻力，多通过四辊薄板弯曲行动随的原则，弯曲的过程中为单一通过和多次通过弯曲。基于对称的做法，以确定该地区的板块推出，在顺利形成弯曲板。分析模型估计上辊位置作为期望曲率半径功能，为多通过三辊形成圆筒，就弹性模量(e)而论实际变动的变形之下可知，计算大于恒定值的。3、总上所述仅有的研究是可利用在连续三辊卷制成形的板材。 试验的分析是难明确地发现上辊位置作为期望曲率半径功能并且它通过非线性规划要求对封闭环形控制或者CNC的用途控制系统可能改进准确性和过程的一贯性，但这样系统承购和维护是昂贵的，并且不是中小规模的卷板制造者可能付得起的对。当前分析的目的将明确开发模型为上辊位置作为期望曲率半径功能
23、为圆柱形壳弯曲因此根据分析和经验主义的方法。 经验模型被开发根据上辊位置对被满载的曲率半径，中心距获得为两下辊半径之间的。在三辊弯曲的过程，在一张或几张通过板材由两个侧辊和满载的曲率半径对通过调整中心上辊。可以改变两侧辊之间的距离。 在变形期间，所有三辊轴被设置互相平行。卷板机的大小由参数定义。例如最大的弯曲半径以板材的最大间距和设计的厚度和相当数量平直的部分保留在板材的端部。4、结论对三辊卷板机分析与实证模型的实验验证，推导出以下重要结论：（1）分析模型基于概念3，它体现了上辊位置是期望曲率半径的函数，简化了计算过程。 （2）实证结果表明，基于概念3的实验和分析结果，证明了有关过程的正确性。 （3）对于中小型规模的生产厂家，由于其生产量小，所以不需要购买自动闭环控制系统，发展模式被证明是估算所需产品机械参数的最简便的工具。（4）在回弹过程，初应变和弹性模量变化的影响，分析/实证模型，将进一步提高上辊位置的计算精度。（5）实证模型在实验研究的基础上，考虑辊之间加载时的曲率分布及辊板接触点的偏移，将更准确地计算上辊位置。
