Design and development of high precision four roll CNC roll bending machine and automatic control model

Area of Science:

• Mechanical Engineering
• Manufacturing Technology
• Control Systems

Background:

• Increasing demand for high-precision bent and rolled components across various industries (aerospace, automotive, shipbuilding).
• Limitations of traditional hydraulic cylinders in achieving accurate profile contours.
• Restricted applicability of existing forming formulas due to material variations and process complexities.

Purpose of the Study:

• To investigate the feasibility of servo electric cylinders in four-roll CNC bending machines.
• To develop a universally applicable automatic control model for profile bending.
• To improve the precision and efficiency of component forming processes.

Main Methods:

• Re-engineering the mechanical structure of a four-roll bending machine.
• Replacing traditional hydraulic cylinders with servo electric cylinders for enhanced control.
• Utilizing actual profile forming curvature (R) and servo electric cylinder feed (d) values.
• Implementing curve fitting methods for an automatic control model.

Main Results:

• Demonstrated feasibility and effectiveness of servo electric cylinders in four-roll CNC bending.
• Achieved higher control precision and faster response times compared to hydraulic systems.
• Developed a universally applicable control model with improved forming precision through iterative trials.

Conclusions:

• Servo electric cylinders offer a superior solution for precision profile bending in CNC machines.
• The developed curve fitting-based automatic control model provides broad applicability and enhances forming accuracy.
• This innovation addresses key challenges in modern component manufacturing, enabling more stringent precision requirements.