Bending Analysis of SS NL Plates on 3-Roller Pyramidal Configuration Bending Machine and Its Experimental Validation

Mechanical Engineering

Three roll pyramidal bending is an effective and efficient metal forming technique, where plates are bend to a desire curvature using forming rolls. Three roller sheet forming process is the most widely used techniques for manufacturing asymmetric hollow shapes, basic component of cylindrical vessels and structures used for different engineering applications. This roll bending process is to be useful consideration by manufacturing industries for producing large, thick parts such as the conical shaped of a turbine runner and of a wind turbine tower, bending of leaf spring. It is necessary to bend the metal sheet smoothly and safely, without cracks and damage working for long life. During bending the sheet metal, stress and strain is developed in the sheet. It is important that the stress and strain are within the limits of the material properties such as S.S. and the factor of safety desired by the engineering applications. Also, there must be maximum vertical displacement of top roller allowed without endangering crack formation in work piece obtained. Three-roll pyramidal roll bending process primarily related with calculating the top roller positions and the stress and strain developed during displacement of top roller for different thickness of the sheet metal. By using the ANSYS software in this study three dimensional dynamic Finite Element (FE) model of a pyramidal three roller bending process is developed. The simulation results are compared with experimental result with three roll pyramidal bending machine. Maximum vertical displacement of top roller allowed without crack in SS plate is observed as 10 mm from FEA results. From FEA and experimental results comparison strain values are in conformance matches with each other with maximum variation of 8.4 % which validates the FEA results. The limit of maximum vertical displacement of top roller is 10 mm, within which the Von mises stress is less than the stress value of material of SS NL plate.

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