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Abstract Rolling technology with rigid arc rollers presents an innovative approach for the rapid manufacturing of three-dimensional surface components. This method employs a pair of rollers, each possessing a distinct curvature (convex and concave), which act as forming tools. The unique design generates a variable gap between the rollers, applying lateral bending and uneven compression to sheet metal, thus producing components with complex curvatures. Variations in the axial cross-section of the rollers lead to differential linear speeds between the surfaces of the convex and concave rollers, significantly influencing the morphology of the formed three-dimensional surface parts. Adjusting the rotational speed ratio of the rollers results in changes to the linear speed of rollers, which markedly affects the shapes of the components. Employing finite element simulation and experimental studies, this research investigates the effects of rotational speed variations on the bending deformation and dimensional accuracy of three-dimensional surface parts. The results reveal that increasing the rotational speed ratio initially enhances the longitudinal curvature of saddle-shaped parts, which then stabilizes, while the transverse curvature decreases. In spherical components, the longitudinal curvature diminishes and then stabilizes, with minor alterations in the transverse curvature. The degree to which the roller rotational speed ratio impacts curvature intensifies with increasing sheet metal compression. These findings suggest that the roll rotational speed ratio can be used as a new process parameter to enhance the curvature range and surface precision of formed parts.
Guan et al. (Mon,) studied this question.