Numerical Simulation Analysis for Padding Assisted Roll-Bending Process

Abstract

Padding assisted roll-bending process is an advanced method to manufacture cylindrical thin-walled structure with variable thickness. A finite element model was established to study the deformation behavior of the padding assisted roll-bending process. In the numerical simulation model, aluminum sheet was selected as an elasto-plastic model, and nylon material was as an elastic model. The research results show that the radius of roll-bent thin-walled aluminum cylinder decreases with increasing of padding material’s stiffness, decreasing of the thickness ratio of nylon-to-metal and increasing of the roller stroke, and that an appropriate thickness compensation of padding material can improve the curvature consistency of cylindrical thin-walled structure with variable thickness.