Simulation and software design of continuous flexible roll bending process for three dimensional surface parts

•Establish longitudinal and transverse mathematical models to predict final shape.•Design software to control sheet metal forming process.•Numerical simulations are carried out to validate the mathematical models.•Experimental tests are performed to verify the software system.

Continuous flexible roll bending process, due to its advantages of flexibility and continuous roll forming, exhibits a great ability to manufacture three dimensional surface parts effectively. To obtain a final part with desired shape and eliminate the need to depend on the experiences and skills of the operator, the longitudinal and transverse mathematical models were presented for predicting the curvatures in sheet metal forming process. A software system, which was guided with the automation and precision producing concepts, was designed based on the mathematical models for controlling the continuous flexible roll bending process. The algorithms of the mathematical models were verified by comparisons of the desired and the numerical simulation results. An application experiment for saddle surface part was performed using the developed software. Compare the experiment result with the target shape, it shows that the software system is reliable.