Roll bending
Roll bending is an essential forming process used to give precise and uniform curvatures to aluminium and steel sheets. This method is based on the controlled action of synchronized rolls that progressively bend the material until the desired shape is achieved.
It is a particularly important process for the production of components destined for the aeronautics and aerospace sectors, such as aerostructures and structural parts of civil and military aircraft, including structural panels and external skins. The accuracy of this process is crucial to ensure the optimal integration of components within aircraft structures, meeting strict standards and minimal tolerances.
Sheet roll bending simulation
Thanks to the DEFORM software, every aspect of the roll bending process can be simulated and optimized, significantly improving production efficiency and the quality of the final product. Simulation makes it possible to predict the behavior of the material during forming, avoiding problems such as waviness, non-uniform bends or unwanted deformation.
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The program also makes it possible to analyze and fine-tune operating parameters such as roll speed, applied forces and bending sequences. This approach eliminates the need for repetitive physical trials, reducing production costs and times, and ensures uniform and repeatable processing on steel and aluminium sheets.
DEFORM is an innovative and complete solution for optimizing the roll bending process, offering numerous advantages:
Accurate prediction of material behavior, ensuring precise, defect-free processing;
Optimization of operating parameters, tailoring them to the characteristics of the component;
Elimination of energy and material waste thanks to virtual trials;
Superior quality and uniformity, essential for high-precision applications.
With the ProCAST and DEFORM predictive software, companies can successfully tackle the challenges of producing aerostructures and structural parts for civil and military aircraft, ensuring safe, high-performing components that comply with the highest industry standards.
Multiple benefits with DEFORM
- Quality improvement
- Optimization and saving in the design
- Improvement of production
- Increased accuracy
- Ease of use
- Reduced computation times
- Reduction of rejects in production
- Cost savings
In the automotive, electronic and medical industries, the level of excellence currently demanded of these products requires features, both of the product and equipment, driven ever more to guarantee compliant results.
These components are made with presses of up to 1,500 strokes/min and with progressive dies made with extremely efficient materials and technologies.
The DEFORM simulation software of the production process, already at the initial stage of an industrialization process, makes it possible to assess the feasibility and quality of the results.
Assessing the deformation conditions, with equal process parameters, makes it possible to determine which is the most suitable solution to best achieve each individual operation, also highlighting the accumulation of stress on the component.
The operations in sequence are then further optimised to limit temperature and wear of all the involved tools.
The thirty-year experience with this type of product and the intuition provided every day in the delicate design stage, are supported by the bending process simulation with DEFORM software, which, through numerical values and clear and easy results, makes it possible to immediately verify the effectiveness of the new solutions proposed.
What customers say
The American DEFORM software, dedicated to the simulation of roll bending processes, has been designed and optimized to ensure maximum accuracy, speed and extreme ease of use.
- EXCELLENT ALIGNMENT BETWEEN “SOFTWARE RESULTS” AND “REALITY”
DEFORM is the most widely used roll bending simulation software in the world. - SAMPLING SUCCESSFUL RIGHT AWAY Simulation makes it possible to identify the defects produced during roll bending, understand their causes and therefore take the right corrective actions.
- START-UP TIMES REDUCED TO A MINIMUM The setup of the various stands has already been tested in simulation. The real sampling will have the set-up sheet for the rolling stands already defined.
- DEFINITION OF THE REQUIRED MOTOR TORQUEDEFORM indicates the torque required for each individual roll and therefore indicates the motors needed for the process. Planning of sampling and production.
- INCREASED ROLL LIFE Tool wear reduced to a minimum thanks to optimization of the process parameters. Part damage phenomena eliminated because they are predicted and therefore resolved in simulation.
For information on purchase, rental or to request a DEMO of the software, or to take advantage of a customized simulation service offered by our technical department, contact us at +39 030 3365383 or fill in the form at the bottom of the page.
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