Continuous flexible forming of three-dimensional surface parts using bendable rollers

A novel idea to form three-dimensional (3D) sheet metal parts using three bendable rollers is presented. It can realize a continuous flexible forming of sheet metal. The forming principle is introduced and forming equipment with three bendable rollers has been developed. The bendable roller with shape-adjusting device is designed based on a flexible shaft of steel wires. Some experiments were performed and typical 3D surface parts were formed. The experiments show that the transversal spine of 3D part is determined by the bended shape of the bendable rollers, and the longitudinal spine of the 3D part is determined by the relative displacement among the top roller and the two bottom rollers. The technology of forming 3D surface sheet metal using bendable rollers can produce 3D surface parts in a rapid and economical way.