中文摘要：

为实现曲面零件的快速成形,提出基于可弯曲辊轧制连续成形三维曲面的新方法。在弯曲辊轧制过程中,通过控制上、下成形辊的辊缝分布,使板料在沿垂直于轧制方向产生弯曲变形的同时,在板料厚度方向不均匀减薄,从而导致沿轧制方向的弯曲变形,随着成形辊的转动,板料被连续成形,最终形成三维曲面零件。阐明曲面的形成机制,建立曲面轧制成形控制的理论与方法。对成形过程中板料厚度方向变形与轧制方向变形之间的关系进行分析,给出轧制方向弯曲变形曲率的计算公式,建立辊缝及轧辊轮廓曲线的计算方法。研制小型试验装置,进行典型曲面件的成形试验,并对凸曲面与鞍型曲面的成形结果进行测量与分析,结果表明,成形曲面的成形误差不超过1.2 mm,说明连续轧制方法用于成形三维曲面零件具有可行性与有效性。

英文摘要：

To realize rapidly forming of three-dimensional surface parts, a new process for continuously forming surface parts based on the rolling using bended rolls is proposed. By controlling the gap distribution between the upper and lower forming roils in the rolling process, the sheet metal is nonuniformly thinned in thickness direction while it is bent in the direction perpendicular to that of roiling, which leads to bending deformation in rolling direction. With the rotations of the forming roils, the sheet metal is continuously deformed and a three-dimensional surface part is formed finally. The formation mechanism of curved surface is set forth, the theory on roll-forming of surface and controlling method for forming process are presented. The relationship between the deformation in thickness direction and that in rolling direction are analyzed and the formulation to evaluate the curvature in rolling direction is given, the methods to compute the gap between two rolls and the profiles of two rolls are provided. A small experimental device is developed and the continuous roll-forming tests for typical surface parts are carried out. The forming results of convex surface and saddle shaped surface parts are measured and analyzed, the analyzed results show that the shape errors of the formed parts are less than 1.2 ram. It is demonstrated that the proposed process is a feasible and effective way of forming three-dimensional surface parts.