Rolling technology based on arc-shaped rollers is a novel method for rapid manufacturing of 3D curved parts. The method uses a pair of arc-shaped rollers (a convex roller and a concave roller) as forming tools, forming an unevenly distributed roll gap. The sheet metal has both transverse bending and longitudinal uneven extension during rolling, so that surface parts with double curvature are processed. The curvature of the formed surface part can be changed by changing the rolling reduction. Changing the vertical distance between the rollers will cause the overall change of the roll gap height, which will inevitably have a great impact on the forming effect of formed 3D curved parts. In this paper, a finite element model and experiment with different rolling reductions was designed; the influence of rolling reduction on the bending deformation and shape accuracy of formed 3D curved parts was studied. The results show that, with the slight increase of rolling reduction (from 0.04 to 0.12 mm), the longitudinal bending deformation of the formed 3D curved part increases significantly, but its transversal bending is almost not affected. When the maximum rolling reduction is 0.04 and 0.06 mm (the corresponding minimum rolling reduction is less than or equal to zero), the shape accuracy of the formed 3D curved parts is not good enough; when the maximum rolling reduction is greater than 0.06 mm (the corresponding minimum rolling reduction is greater than zero), the shape accuracy of the formed 3D curved parts is significantly better. This indicates that, for the rolling of 3D curved parts based on arc-shaped rollers, ensuring that the minimum rolling reduction is greater than zero is the key to ensuring good shape accuracy of the formed 3D curved parts.

中文翻译：

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轧制减量对3D曲面零件轧制工艺影响的研究

基于弧形滚子的滚压技术是一种快速制造3D曲面零件的新方法。该方法采用一对圆弧形辊（凸辊和凹辊）作为成型工具，形成不均匀分布的辊缝。金属板在轧制过程中既有横向弯曲又有纵向不均匀延伸，从而加工出双曲率的表面零件。通过改变轧制率可以改变成形表面部分的曲率。改变辊子之间的垂直距离会引起辊缝高度的整体变化，这势必会对成型的3D曲面零件的成型效果产生很大的影响。本文设计了不同轧制压下率的有限元模型和试验；研究了压下量对成形3D曲面零件弯曲变形和形状精度的影响。结果表明，随着轧制率的轻微增加（从0.04到0.12 mm），所形成的3D弯曲零件的纵向弯曲变形显着增加，但其横向弯曲几乎不受影响。当最大压下量为0.04和0.06mm时（对应的最小压下量小于等于0），成型3D曲面零件的形状精度不够好；当最大压下量大于0.06mm（对应的最小压下量大于零）时，成型3D曲面零件的形状精度明显更好。这表明，对于基于弧形滚子的 3D 弯曲零件的滚压，