中文摘要：

连续辊压成形是一种板料成形新方法，采用两个弯曲的成形辊可加工出三维曲面零件。对连续辊压中从板料到曲面的变形过程进行力学分析，并对变形与材料模型进行简化，根据成形曲面中的内力平衡方程，建立控制纵向（成形辊滚动方向）弯曲变形的基本方程，给出由辊压应变计算纵向弯曲曲率半径的公式及上、下成形辊之间辊缝的设计方法。分析表明，当辊压初应变在截面高度方向线性分布时，最终的成形曲面中没有残余应力，纵向弯曲变形的曲率由横截面上的最大高度差及横截面上压缩率差这两个参数来决定。通过分析得到实现曲面辊压成形的条件，获得横截面上压缩率差以及成形曲面几何参数对纵向弯曲的影响规律。通过曲面连续辊压成形的实例，说明所提出理论与公式的有效性。

英文摘要：

Continuous roll forming（CRF） is a new forming method for sheet metal, the three-dimensional surface part can be formed by using two bended forming rolls. The mechanical analysis on the deformation process from sheet blank to the curved surface in CRF is carried out, the deformation and material models are simplified, according to the equilibrium of internal force in the formed surface, the basic equations for governing bending deformation in longitudinal direction（rolling direction of forming rolls） are set forth, the formulations for calculating the radius of bending curvature in longitudinal direction based on the rolling strain are presented, and the method to design the gap between the upper and lower rolls is given. Analysis results show that, when the initial rolling strain is linearly distributed in the height direction, there are no residual stresses in the final formed surface, in addition, the bending curvature in longitudinal direction is determined by the maximum height difference and the compression ratio difference in the cross-section. Through the analyses on the process of CRF, the condition to realize the continuous roll forming for curved surface is achieved and the effects of the compression ratio difference and the geometrical parameters of the curved surface on the bending deformation in longitudinal direction are obtained. Experimental examples of CRF verify the effectiveness and practicability of the proposed theory and formulations.