Mechanical Design And Structural Analysis Of Small Roll Forming Machine

Now roll forming production line is generally long, which not only takes up space, but also installation and commissioning will spend a lot of time and energy. Considering the convenient of materials, if the roll forming machine can be transported to the field production, it will save profile transport process, improving the production schedule. Therefore, it is necessary to design a small roll forming equipment to meet this need.Based on the existing roll forming equipment, a small roll forming machine was designed. It mainly had the characteristics of miniaturization and simplification; two kinds of roll flower and roller drawing were designed; the finite element model of roll forming of double standing seam was established using finite element software ABAQUS, and the two schemes were simulated respectively; Besides using orthogonal simulation test study of side whipstitch plate roll forming process; Finally, the kinematics and dynamics simulation of main mechanism was done.It can not only adjust the width adapting to the different width of plate types, but also box can be turned over to achieve a set of equipment installed two sets of rollers. The most important is that it can be transported to the construction site to product directly avoiding the limitations of direct delivery of products. According to the requirements of the small roller bend forming machine work, based on the construction site safe, reliable and compact structure design principle, the main components of the proposed design scheme and the overall layout. The design scheme and the overall layout of main components is put forward according to the work requirements of the small roll forming machine and the construction site safe, reliable and compact structure design principle. Transmission devices and the main structure parts are carried on the detailed mechanical design.Compared between equivalent stress and equivalent strain of corners of two schemes, the second program is better than the first program.And then the forming mechanism of double standing seam sheet is analyzed deeply, obtaining the change rule of displacement field, the the longitudinal strain of edge, thickness change both inside and outside corners and transverse strain along the width direction. And through the lateral strain simulation values compared with the theoretical value to verify the accuracy of the model. The model can be thought accurate by compared simulation value of transverse strain with theoretical value. Orthogonal experiment was used to study the influence of forming springback angle from the thickness, pass pitch, the roller radius and forming velocity. The results show that the influence of thickness is biggest to springback and less susceptible to the interference of other factors. The sensitivity of forming velocity and the roller radius rank only second to thickness and the sensitivity of pass pitch is minimum. Among these three factors, the thickness is most sensitive to springback. If the bending Angle and the corner radius are equal, the more the sheet thickness, the greater the plastic deformation area of corner part. After unloading springback is smaller. The variance analysis is carried on to analyze accurately and verify results of orthogonal experiments. The significant analysis results of various factors between variance analysis and range analysis is coincident, which further enhances the reliability of the conclusion.The kinematics simulation of screw-slider mechanism and main transmission mechanism have been earried out based on ADAMS Through the kinematics simulation of screw-slider mechanism, it shows that the fluctuation of driven sprocket angular velocity curve, and use the result is analyzed by polygon effect in the process of chain transmission. The displacement, velocity and acceleration curve of box are got the results and also get, and they completely conform to the situation in the process of actual operation. The kinematics simulation was carried out on the main drive mechanism, angular velocity of the guide pillar, left roller shaft No.2and right roller shaft No.2, three output shaft angular velocity have some fluctuations, the guide pillar movements are small, and the angular speed fluctuation of left roller shaft No.2and right roller shaft No.2are bigger, this is because the transmission process should not only affected by the chain polygon effect, but also will be affected by periodic meshes into the tooth gear transmission of shocks. Finally on the cutter body dynamics simulation, and the angular velocity of synchronous belt, tension, Z axis displacement are studied, analyzed its movement characteristics, in line with the movement regularity of synchronous belt, then displacement, velocity and acceleration of hob is analyzed. It is concluded that the equipment is stable and reliable and conforms to the actual requirements.