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Roller plunge schedule design and finite element analysis on roller flattening of metal sheets.

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Title: Roller plunge schedule design and finite element analysis on roller flattening of metal sheets.
Authors: Hwang, Yeong-Maw1 (AUTHOR), Wang, Guan-Yu1 (AUTHOR), Tsui, Hiu-Shan Rachel1,2 (AUTHOR) racheltsui@must.edu.tw
Source: International Journal of Advanced Manufacturing Technology. Nov2025, Vol. 141 Issue 5/6, p2863-2875. 13p.
Subject Terms: *SHEET metal, *RESIDUAL stresses, *CURVATURE, *ALUMINUM sheets, *FINITE element method
Abstract: This study presents a systematic investigation into the effects of roller plunge schedules on curvature gradients, residual stress distributions of the flattened sheets during roller flattening of metal sheets. A 3D finite element modelling is developed to simulate the roller flattening process and examine the impacts of roller plunge schedules and dimensions of the roller flattening mechanism. Experiments on roller flattening of 6061-T6 aluminum sheets are conducted using a self-designed nine-roller flattening machine. Experimental curvature gradients are compared with finite element simulation results to validate the finite element modelling and the proposed roller flattening plunge schedule schemes. Simulation results indicate that the second roller plunge significantly influences curvature gradients and residual stress distributions of the flattened sheets. Adjusting roller plunge ratios can effectively improve the flatness of sheets with an initially single-curvature or complex double-curvature. A higher plastic region ratio on the cross section of the flattening sheet can substantially improve its flatness and stress uniformity in challenging double-curvature scenarios. The developed roller plunge design schemes exhibit excellent adaptability and can integrate adjustable multi-roller pitch and vertical positioning for diverse applications. [ABSTRACT FROM AUTHOR]
Database: Academic Search Index
Description
Abstract:This study presents a systematic investigation into the effects of roller plunge schedules on curvature gradients, residual stress distributions of the flattened sheets during roller flattening of metal sheets. A 3D finite element modelling is developed to simulate the roller flattening process and examine the impacts of roller plunge schedules and dimensions of the roller flattening mechanism. Experiments on roller flattening of 6061-T6 aluminum sheets are conducted using a self-designed nine-roller flattening machine. Experimental curvature gradients are compared with finite element simulation results to validate the finite element modelling and the proposed roller flattening plunge schedule schemes. Simulation results indicate that the second roller plunge significantly influences curvature gradients and residual stress distributions of the flattened sheets. Adjusting roller plunge ratios can effectively improve the flatness of sheets with an initially single-curvature or complex double-curvature. A higher plastic region ratio on the cross section of the flattening sheet can substantially improve its flatness and stress uniformity in challenging double-curvature scenarios. The developed roller plunge design schemes exhibit excellent adaptability and can integrate adjustable multi-roller pitch and vertical positioning for diverse applications. [ABSTRACT FROM AUTHOR]
ISSN:02683768
DOI:10.1007/s00170-025-16864-2