Finite element analysis of effects of parameters on in-plane bending process of strip metal

In-plane bending of strip metal under unequal compressing with conical rollers is an advanced precision forming process that can be used for producing rings with good flexibility, high efficiency, and low consumption, making use of unequal deformation. In this paper, the effects of the process parameters on the inner radius value of a formed ring are analyzed systematically by means of the rigid–plastic FEM. The effective parameters include the geometrical parameters describing the degree of unequal deformation, the boundary condition referring to the friction factor, and the material properties. The analytical results are in good agreement with experimental results. The research indicates that: (1) the inner radius value depends on the geometrical parameters; (2) the material properties have an effect on the geometrical parameters; and (3) the effect of the friction factor on the inner radius value may be ignored, but even a low value of the friction factor can improve the surface quality of the formed ring. The results are helpful to the understanding, design and optimization of the process.