Abstract A 3D profiled blank (3D-PB) is a variable thickness in both the rolling direction (RD) and transversal direction (TD). A novel method of manufacturing 3D-PB is proposed in this paper. The method combines two processes: first, the workpiece of a normal blank is rolled into a tailor rolled blank (TRB) through variable gauge rolling (VGR), then the TRB is rolled into a 3D-PB through variable thickness rolling (VTR). A significant modification was made to VGR as the original VTR could not be adapted to the production of 3D-PB. The metal flow of the thick and thin areas of the 3D-PB was investigated with finite element simulation. The metal in the thin area mainly flows in the TD. The deformation of the workpiece was studied during the process. The workpiece was first bent and then thinned, resulting in a different width between the thick and thin areas. The thickness difference between the thick and thin areas of the 3D-PB was explained through simulation and controlled rolling experiments. The final 3D-PB has a variable thickness in both the RD and TD with good shape.

中文翻译：

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3D异形坯变厚轧制试验与仿真

摘要 3D 异型坯 (3D-PB) 在轧制方向 (RD) 和横向 (TD) 上的厚度都是可变的。本文提出了一种制造 3D-PB 的新方法。该方法结合了两个过程：首先，将普通毛坯的工件通过可变规格轧制（VGR）轧制成拼轧坯（TRB），然后通过可变厚度轧制（VTR）将TRB轧制成3D-PB。由于原始 VTR 无法适应 3D-PB 的制作，因此对 VGR 进行了重大修改。用有限元模拟研究了 3D-PB 厚区域和薄区域的金属流动。薄区金属主要沿TD流动。对加工过程中工件的变形进行了研究。工件先弯曲后减薄，导致厚区域和薄区域之间的宽度不同。通过模拟和控制轧制实验解释了 3D-PB 厚区域和薄区域之间的厚度差异。最终的 3D-PB 的 RD 和 TD 厚度可变，形状良好。