Distortion minimization of roller offset formed aluminum sheet through finite element model simulation

Abstract

Roller offset forming machine is a machine that is capable of incremental forming metal sheets through an automatic change of tools. Thus, the machine is the key to small-quantity batch production of automobiles. Roller offset forming (ROF) is one of many functions of the roller offset forming machine, a new technique to create an offset to a metal sheet incrementally generated by two rollers. The ROF is applicable for manufacturing various shapes and sizes of sheet offset forming without demanding new tools. However, the roller offset forming process induces an unwanted distortion throughout the aluminum sheet, resulting in a product's asymmetric and unstable geometrical feature. This thesis provides the optimum way of producing distortion-minimized aluminum sheets without changing the tool and the machine of the ROF. From finite element model analysis, manufacturing parameters were calibrated to minimize distortion.