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UDC. 629.78 D. I. CHERNYAVSKY

DOI: 10.25206/1813-8225-2023-186-44-54
D. D. CHERNYAVSKY

Omsk State
OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

Technical University,
Omsk

STUDY
ELASTOPLASTIC BENDING OF SHEET
BLANK
VARIABLE THICKNESS
WHEN ROLLING IT
The work analyzes the technological process of rolling a sheet blank to obtain a
cylindrical shell of large diameter. The analysis was carried out on the basis of
strength calculations of elastoplastic bending of a sheet blank, taking into account
the springing effect. Calculation of springing was carried out on the basis of the
existing ratios of the energy of plastic and elastic deformations formed in the
material of the sheet workpiece. Conclusions are drawn and practical
recommendations are given that can be used in the process of adjusting the
technological parameters of rolling machines.

Key words: cylindrical shells, elastic and plastic deformations, radius of curvature,
energy of formation of elastic and plastic deformations, technological parameters
of rolling.

Introduction.Currently, in various Industrial sectors Sov M.I. et al. systematize and generalize research on the
widely use technological processes associated with cold processes of forming parts made of sheet metal and
metal forming, and in particular with sheet stamping. profiles, using the obtained analytical dependencies to
This method of material processing is based on the determine the curvature and movement of the neutral
process of plastic change in the shape of the workpiece, layer of a plastically curved element under various
which is: a sheet of metal obtained by rolling; strip or loading schemes. In publications [9, 10], the authors
tape rolled into a roll. Sheet stamping in combination present calculation methods for determining the power,
with welding makes it possible to obtain thin-walled tuning and programmable parameters of bending
structures of various sizes and shapes that cannot be equipment intended for the manufacture of parts from
produced by other methods. Such components have high sheet and profile materials, taking into account the
manufacturing accuracy together with high quality of geometric nonlinearity generated by the bending
roughness and surface cleanliness of the part. process. In works [11–15], the authors consider individual
issues related to the technology of milling and
subsequent rolling of wafer shells based on various
methods of material processing that exclude
However, to apply such technological processes, it is deformation of the workpiece in non-rigidly fixed places,
necessary to solve various scientific and technical taking into account the shaping of a given geometric
problems associated with determining the parameters of shape of the processed structural elements.
structures of minimum mass with the required load-
bearing capacity. In [1], the issues of designing shell
structures of minimal mass with the choice of materials,
design schemes, safety factors, material efficiency This publication will discuss issues related to the
criteria, as well as the strength of these thin-walled power calculation of the technological process of rolling
structures are considered. In works [2–4], the authors smooth plates. In particular, the effect of springing will
consider various cases of complex resistance, curved be considered. The designations of physical quantities
rods and shells, stresses in thick-walled and thin-walled adopted in this article are given in Table. 1.
vessels of various types. Volmir A.S. in work [5] studies
various cases of calculating the stability of compressed Formulation of the problem.For the manufacture of
rods and rod systems, as well as shells, taking into cylindrical Metal sheets of various thicknesses are used
MECHANICAL ENGINEERING

account various situations of load application. Grigolyuk for large-diameter or conical workpieces. By large
et al. [6] consider non-classical theories of vibrations of diameter we mean product diameters greater than 1.5
rods, plates and shells. In works [7, 8] Ly- m.
To form a cylindrical surface, a flat rectangular sheet
44 of metal is placed on the two bottom rolls of a three-roll
machine.
 Table 1 Continuation of the table. 1

Notation in formulas
1 2 3

OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

Sim- Size-
V Vanadium
Description
oxen ness
Cu Copper

1 2 3 Mg Magnesium

Pressing force of the thrust roll against the

F N H.R.C. Rockwell hardness
workpiece

The force of pressing the thrust roll against the HB Brinell hardness
F 1+Δ N
workpiece, taking into account springing
σpc Material proportionality limit MPa
Torque rotating the feed rollers
T N∙m Ultimate strength (tensile
σV MPa
strength) of the material
Radii of the corresponding roll numbers
ri m Hardened carbon tool steel
M1
Current radius of curvature of the sheet
ρ(z) m Partially Annealed Tool Steel
stock M2
Distributed load bending a sheet blank
q N/m
M3 Annealed Tool Steel

R,0R, Reactions of sheet stock support and M4 Duralumin, Russian analogue of D16
A N
RB lower rolls
Aluminum, Russian analogue of ADS
h Sheet thickness m M5
(technical aluminum)
Distance between centers of lower rolls M6 Pressed lead
l m

L Bending length of the workpiece sheet m

Young's modulus of the upper roll and sheet

E,1E Pa
2 material
Poisson's ratio of the upper roll and sheet
µ,µ –
1 2 material
Width of the contact area between the workpiece
b m
and the upper roll

nn Current cross-section of the workpiece, Fig. 6 –

Equation of transverse bending of the

Y(z) –
workpiece, Fig. 6

f(z) Equation of workpiece deflection, Fig. 6 –

Current coordinate of the workpiece

z m
cross-section, Fig. 6
Rice. 1. Hydraulic rolling machine
Moment of inertia of the cross-sectional CNC machine for sheet metal bending
Jx m4
area of a workpiece of lengthL

a Coordinate of the force application pointF m

Coefficient relating quantities aAndl

χ –

Coefficient relating quantities zAndl

ξ –

Axial moment of resistance of the cross-

Wx sectional area of the workpiece length L for m3
elastic deformations
Axial moment of resistance of the cross-
W pl sectional area of the workpiece length L for m3
plastic deformations
Total energy of workpiece forming
AΣ J

Energy of elastic deformations during Rice. 2. The process of rolling sheet metal using a
A J three-roller rolling machine
control
workpiece shaping
Energy of plastic deformations during
A layer J
workpiece shaping
(Fig. 1–3). Rotational motion during the operation of this
MECHANICAL ENGINEERING

C Carbon
machine is communicated only to the two lower work
Mn Manganese rolls 3, which can horizontally move closer to each other
or move away from each other to change the distance
Cr
between the longitudinal axes of the rolls. This is
Chromium

W necessary to change the diameter formed by the

Tungsten 45
cylindrical surface
OMSKY N

Rice. 3. Conventional Rice. 4. Installation of the workpiece

diagram of sheet metal rolling on the machine: 4 - additional
on a rolling machine (supporting the workpiece) rolls
with three rollers:
1 - sheet blank, 2 - upper
(thrust)
roller, 3 - lower
(feed) rollers

sti. The upper roller of this machine 2, which is called the

thrust roller, rotates due to frictional forces arising
between its surface and the surface of the metal sheet 1
being processed.
This roller has the ability to move in the vertical
direction, pressing the workpiece against the lower
rollers with a given force. Additionally, the upper roller
can be tilted to the side to release the finished product,
as well as to quickly replace it with a roller of a different Rice. 5. Calculation scheme
diameter to obtain a product with different geometric for bending sheet edges
parameters.

In practice, manufacturing enterprises do not design

rolling equipment themselves, but purchase it from It is proposed to consider the relationship between the
specialized domestic and foreign manufacturers. energies of elastic and plastic deformation of the
Approximate technical and technological workpiece material, which are formed in the bending
recommendations from manufacturers on the selection zone.
of machine tool settings for the production of specific Theory.To solve the problem at hand, It is necessary
products are in many cases not suitable. Therefore, the to divide the rolling operation into several stages. This
buyer of machine tools has to select their optimal setting article will discuss the first stage - installing the
modes by trial and error to obtain minimum residual workpiece on the machine and bending the edges of the
stresses, a given curvature and other required sheet (Fig. 4).
parameters of the manufactured product. At this stage of the rolling operation under
consideration, it is necessary to form a bend on its right
edge on a flat sheet of the workpiece. In this zone there
In the process of rolling a sheet of metal, the so- will be a longitudinal weld seam necessary for the
called"spring effect".The spring angle when bending manufacture of a cylindrical shell (Fig. 4).
sheet material or profiles is the angle through which a
workpiece bent to a given radius of curvature is unbent Direct bending of the workpiece occurs due to
due to the elasticity of the material after the load is contact stresses and deformations that occur when
removed. The magnitude of the springback angle thrust roller 2 is pressed onto the upper surface of sheet
depends on the geometric, strength, force and other 1. However, these stresses depend on the elastic
factors acting in the process of rolling the workpiece. In properties of the material and are not a linear function of
practice, technological processes taking into account the the load, since with increasing load the dimensions of the
springing effect have been well established contact area increase. The reference book [16] provides
experimentally for rolling pipes due to their mass expression (1) for calculating the size of the contact strip
production. of the cylinder and a cylindrical cavity with parallel axes
(Fig. 5).
The production of cylindrical blanks with diameters of
more than 1.5 m is much less common, since mechanical
engineering products using such components, as a rule, Frρ(z1) -1 - μ2 1 - μ22-.
relate to small-scale or individual production. Therefore, b-2,256 - --
1
- -- (1)
MECHANICAL ENGINEERING

L -(z) - r1- E1 E2 -
technological errors when rolling such workpieces can
lead to costly product defects.
To determine dimensionsbuse data physical
properties of materials given in publication [17] and in
46 In this work, to compensate for the effect of springing table. 2 and table. 3. We will use hardened carbon steel
during the rolling of sheet blanks, as the material for the rolls.
 table 2

Physical characteristics of materials to determine width of the

zone of action of Hertz contact stresses [17]

OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

Mate- E,
σ,pcMPa σ,V MPa µ Hardness Alloying elements, %
rial 1∙105MPa

M1 2,041 937.7 1245 0.286 60-64 HRC C 0.90 Mn 1.20 Cr 0.50 W 0.50 V 0.20
M2 2,041 489.5 970 0.286 17-32 HRC C 0.90 Mn 1.20 Cr 0.50 W 0.50 V 0.20
M3 2,041 206.8 655 0.286 6-12 HRC C 0.90 Mn 1.20 Cr 0.50 W 0.50 V 0.20
M4 0.731 365.4 477 0.33 74 HB Cu 0.90 Mn 1.20 Mg 0.50 – –
M5 0.731 82.7 132 0.33 24HB No data
M6 0.237 8.3 9.03 0.45 No data

Table 3 5. M1 and M5.

Physical characteristics of calculated quantities

2 -104 0.32 -1.5
for determiningcoverage area width -
Hertzian contact stresses 4 (1.5 - 0.32)
b-2,256 - -0.161mm.
-1 - 0.2862 1 - 0.332 -
- -- - -
Magnitude Magnitude -2.04 -10eleven 7.31-1010- -
Parameter Parameter
parameter parameter
6. M1 and M6.
L 4000 mm = 4 m F 20000 N

r1 320 mm = 0.32 m ρ 1500 mm = 1.5 m 2 -104 0.32 -1.5

-
4 (1.5 - 0.32)
l 500 mm = 0.5 m b-2,256 - -0.244 mm.
-1 - 0.2862 1 - 0.452 -
- -- - -
-2.04 -10eleven 2, 37 -1010--

tool steel (M1). As a workpiece material, we consider all Thus, it can be noted that the width of the zone of
types of materials given in Table. 2. action of contact stresses during rolling of cylindrical
shells of large diameter is small compared to the
1. M1 and M1. geometric dimensions of the workpiece and rollers.
Therefore, in theoretical calculations of sheet bending
2 -104 0.32 -1.5 processes, the force effect on the workpiece from the
-
4 (1.5 - 0.32) side of the thrust roll can be assumed to be concentrated
b-2,256 - -0.118 mm.
-1 - 0.2862 1 - 0.2862- under the condition ρ >r. 1
- -- - - To determine the support reactions, transverse forces,
-2.04 -10eleven 2.04 -10eleven--
bending moments acting on the workpiece, as well as to
calculate the values of its deflections and angles of rotation
2. M1 and M2. of the sections, it is necessary to draw up a calculation
diagram for the bending of the workpiece (Fig. 6).
2 -104 0.32 -1.5 When calculating, we will make the following assumptions. 1.
-
4 (1.5 - 0.32) At the considered stage of rolling the bottom
b-2,256 - -0.118 mm. The rollers do not rotate.
-1 - 0.2862 1 - 0.2862-
- -- - - 2. As is known, stressed and deformed
-2.04 -10eleven 2.04 -10eleven-- the condition of the workpiece during bending depends

3. M1 and M3.

2 -104 0.32 -1.5

-
4 (1.5 - 0.32)
b-2,256 - -0.118 mm.
-1 - 0.2862 1 - 0.2862-
- -- - -
-2.04 -10eleven 2.04 -10eleven--

4. M1 and M4.
MECHANICAL ENGINEERING

2 -104 0.32 -1.5

-
4 (1.5 - 0.32)
b-2,256 - -0.161mm.
-1 - 0.2862 1 - 0.332 -
- -- - -- Rice. 6. Calculation scheme for rolling a workpiece based on
-2.04 -10eleven 7.31-1010- an example of calculating the bending of a two-support 47
statically determinate beam
 on the shape and dimensions of its cross section. For the Equations of transverse bending of a neutral lineY(z)
case under study, we consider the workpiece to be wide, in the case under study are plane curves specified
i.e. its width is incommensurably greater than its explicitly for the functiony=f(x) in the Cartesian
thickness. coordinate system (Fig. 6). In order to determine the
For the design scheme shown in Fig. 6, we define the radius of curvature of the workpiece during rolling, we
OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

reaction equations of the supportsR, shear forceQand use well-known mathematical expressions [18].
bending momentM, using known methods of strength of
materials, [16].
3

(l-a) a - -dY-2-
R0-F , RA - F . (2) -1 - - --
l l - -dz- -. (12)
ρ(z) -
d2Y
For the condition0 -z-awe get the following results: dz2
injuries.
For the condition0 -z-ainsert the expression (7) in (12).
(l-a)
Q(z) -F . (3)
l
EJ2xl
ρ(z) - -
(l-a)z . (4) F(l-a)z
M(z) -F , (13)
l
F2(l-a)2-a-
3
- -
2l-a--3z2-
2
- -1 - -
For the conditiona-z-lwe get expressions of the form: - 36E22J2 2xl -

a Lh3 . (14)
Q(z) - -F . (5) Jx -
l 12

a Expression (13) shows the radius of curvature

M(z) -F(l-z). (6) the neutral line of the workpiece during rolling (Fig. 6). For
l
further analysis, it is advisable to express the quantitiesa
Coordinate of the dangerous section z and the size of Andzin the expression (13) through the valuel, i.e.
0
the max- maximum bending momentM max will be determined express in dimensionless form.
share: For the condition0 -z- aat0 -a-llet's introducea- χl,
Where0 - χ - 1. Then let's write down0 -z-a,0 -z- χl,
a(l-a) z z
z= aAndMmax-F . 0- -1. Let's introduce designation ξ- , Where0 - ξ - 1.
0
l χl χl
Then expression (13) can be rewritten as follows:
Consider the equations of transverse bendingY(z) and
maximum deflectionf(z) neutral line of the workpiece
[16]. E2J x 1
ρ(z) - -
For the condition0 -z-a at 0 -a-l/2we get Fl (1 - χ)χξ
the following expressions. . (15)
- F2l4 -
- -1 - (1 - χ) χ-2 - χ-1 - 3ξ2--
22 2 3
-
Fa2(l-a)2- z z z3 -. - 36E22Jx2 -
(z) - - -2 - - 2 (7)
6EJ2xl - a l- aa ( l- a)- -
Expression (7) will take the form:
For the conditiona-z-lwe get expressions of the form:
Fl3
(z) - - (1 - χ)ξχ2(2 - χ - ξ2χ). (16)
Fa2(l-a) 2 6E 2Jx
Y(z) - - -
6E2Jxl
For the conditiona-z-linsert the expression (8)
- l-z l-z (l-z)3-.
- -2 - - (8) to (12).
- l-a a(l- a)2--
a E2Jl x
ρ(z) - -
Fa(l-z)
The maximum deflection value of the workpiecef(z)
3 . (17)
2-2-
will be determined by the following expressions. - F2a2
- -1 - 36E2 2 2 -a -l-3(l-z) -
2 2

- 2Jxl -
F(l -a)l23 - (l-a2-3 )
f(z) - - -1 -
- l 2 --
27EJ x - -
For the conditiona-z-lat0 -a-llet's introducea- χl,
at
l2- (l-a)2 Where0 - χ - 1. Then let's write downa-z-l,χl-z-l,
z- . (9)
3 z 1 z , Where 1
1- - . Let us introduce the notation ξ - -ξ- .
χl - χl χ
The values of the maximum rotation angles of the Then expression (16) can be rewritten as follows:
MECHANICAL ENGINEERING

workpiece sections will be equal. in general form:

F(l-a)a E2J x 1
θ-- (a-2(l-a))atz=0 (10) ρ(z) - -
6EJxl Fl χ(1 - ξχ)
3
48 Fa - F2l4 -
(l2-a2)atz=l.
χ2-χ2- 1 - 3(1 - ξχ)2-
θ-- 2
6EJxl
(eleven)
- -1 - 36E2 2 -. (18)
- J
2 x -
 Expression (8) will take the form: When bending, as in the case under consideration, the
calculation is carried out using normal stresses distributed
Fl3 (19) divided unevenly along the height of the section (Fig. 7).
Y(z) - χ2(1- ξχ)(χ - 2ξ - ξ2χ).
6E2Jx In the usual case, the permissible bending stresses

OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

are within the limits of Hooke's law. According to Navier's
By analogy, we express expressions (3–6) through the formula, maximum stresses act at the edges of the
quantityl. For the condition0 -z-awe get the following: section (Fig. 7a).
common expressions:
M(z). (24)
(z) -F(1 - χ). (20) σcontrol-
Wx
M(z) -Fl(1- χ)ξ-. (21) Lh2
Wx- . (25)
6
For the conditiona-z-lwe get the equations:
As the load increases, the tense
Q(z) - -Fχ . (22) the state of the cross section of the workpiece passes from
the elastic zone to the plastic flow zone
M(z) -Flχ(1 - ξχ). (23) material. This zone extends from the edges
sections in the direction of the neutral axis (Figure 7b).
As a rule, most methods for calculating the strength The limiting state will occur when plastic deformations
of machine parts are based on assessing the strength of spread over the entire cross section of the workpiece
the material at a dangerous point or section based on (Fig. 7c). After this, further deformation of the section will
permissible stresses. Such voltages are determined from occur without increasing the bending moment. In this
the condition of not achieving a dangerous zone, a so-called plastic hinge is formed. Plastic moment
quantitative values—yield strength (for plastic material) of resistance
or tensile strength
(for brittle material). When processing mother- The resistance of a given cross section is determined by the
pressure problems, it is necessary to proceed not from following expression [16]:
Hooke’s law, but from the appearance of local stresses in
the material being processed, based on its yield strength. Lh2
Wpl- . (26)
Such an assessment of strength is called strength 4
calculation based on the limit state, i.e. when the material
of the structure loses its ability to resist external During rolling, especially in the case where the radius
influences. In our case, excessive deformations develop of the workpiece being bent is much larger than the
in the workpiece from static loads, and under the radius of the rollers, both plastic and elastic zones are
influence of plastic flow, the material of the workpiece formed in the cross section of the workpiece. This is due
acquires to the fact that part of the workpiece in the cross section
Shapes into the desired shape. experiences circumferential tension,
In the theory of metal forming, in order to simplify and its other part is circumferential compression. When
calculations, the Prandtl assumption is introduced, under external loads are removed, tensile layers tend to shorten
which in the stress-strain diagram (σ – ε) the section of their length, and compressed layers tend to increase their
the straight line, expressed length. This causes a change in shape (radius of curvature)
Hooke's compressive law directly transforms into a and size (different thickness) of the workpiece. This
horizontal straight line without a smooth transition [7, 8]. phenomenon is called springing.
The theoretical calculations of springing are based on
Thus, equality is allowed between the limits of A. A. Ilyushin’s theorem on unloading. According to this
proportionality and fluidity. The length of the horizontal theorem, unloading occurs according to Hooke's law. If
section of the diagram is not limited, i.e. the material is the body experienced non-uniform deformation during
considered to be perfectly plastic and not hardened. Such loading, then upon unloading residual stresses will arise
a diagram is called a Prandtl diagram. in it, which are determined by the difference between the
stresses acting in the loaded body and the fictitious
Replacing real stress-strain diagrams with a stresses that would arise in the body during elastic
schematized Prandtl diagram is permissible for steel, deformation of the same curvature [8] .
alloys based on copper and aluminum, as well as for
materials that have diagrams with a limited length of the In specialized literature and reference books there
yield plateau. are other theories, as well as diagrams and graphs for
various metals and alloys. Analysis
MECHANICAL ENGINEERING

49
Rice. 7. Calculation of normal bending stresses
 information shows that the change in bending radius Let's transform expression (33):
depends on the ductility of the metal, the thickness of the
(1 -n )
workpiece, the bending angle and other factors. -A- -A- layer
. (34)
In this work, it is proposed to use the energy nlayer
approach to calculate springing. Absolute and relative
- (1-n layer ) -
OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

data on energy conversion during deformation when A-- -A--A -1-

- -. (35)
pressing a hardened steel ball into various materials - nlayer -
were obtained in [17].
As follows from equation (28), the effect of springing
As is known, the work done by a force on a body is can be compensated in practice only by increasing the
equal to the product of the magnitude of this force and forceF.
the distance traveled by the body. For our case, the Let's rewrite expression (28).
pressure force of the thrust roll isFbends flat sheet of the
workpiece to a certain maximum distancef(z), equation F 2l3 3
A-- -A- -1--- (1 - χ) χ3(2 - χ)3. (36)
(9). Then the deflection energy of the workpiece will be E2Jx 27
determined by the expression:
3
Let us insert equations (28) and (36) into expression (36).
F2(l-a)l23 - (l-a)2-
A--Ff(z) - - -1
- - -- l
2 3
3
27EJ2x - l2 - - F1-- (1 - χ) χ3(2 - χ)3 -
E2Jx 27
at F2l3 3 - )-
l2- (l-a)2. (27) -- (1 - χ) χ3(2 - χ)3 -1 - (1 -nlayer-.(37)
z- E2Jx 27
3 - nlayer -

As before, let us express the quantitiesaAndzin terms of

)-
nii (27) through the quantityl: F1-- -2 F 2--1 - (1-nlayer -. (38)
- nlayer -
F2l3 3
A--Ff(z) - - (1 - χ) χ3(2 - χ)3
E 2Jx 27 1
F1---F . (39)
at nlayer
2 1, 1. (28)
-- - 0-ξ-
3χ 3 χ
Thus, expression (39) shows the magnitude of the
Let us introduce the assumption that the energy of shape pressure force of the thrust rollF, which allows1+Δ
you to
change is spent only on elastic and plastic deformations of the obtain a given radius of curvature ρ of the workpiece,
workpiece, i.e. other energy losses are small. taking into account its springing.
Results of theoretical research.How
- Alayer-1. (29) is known when setting the parameters of the rolling
A control

A- A- machine, you can solve forward and reverse techno-

logical tasks. In the first case, based on the known value
For convenience, we introduce the following notation:
of the machine settings parameters, determine
Acontrol-n Alayer -n dThe curvature of the deformed workpiece is reduced.
And layer.
A- A-
control

The second involves calculating the parameters for setting

Due to the springing effect, additional energy must the rolling process according to a given workpiece curvature.
be added -A, which should to compensate -
for the effect In this case, it is advisable to choose a
of springing and achieve the specified value of the radius a combination of these two methods. First you need
of curvature ρ of the workpiece after the end of rolling. select standard roll settings, and then, using numerical
methods, select the pressure force of the thrust rollF,
which 1+Δ
Acontrol- -Acontrol
- A layer- -Alayer-1. (30) paradise allows you to obtain a given radius of curvature
A -- -A- A-- -A- ρ workpiece taking into account its springing.
Let us assume that the upper (thrust roller) of the
The main condition is that the additional energy of machine is located at the same distance from the centers
plastic deformations must be equal to the energy of of the lower (feed) rollers. This means that the relative
elastic deformations causing parameters have the following meanings:
springing effect --A layer-Acontrol-A-ncontrol
.
a- χl-0.5l; χ -0.5.
Acontrol- -Acontrol- Alayer-A-ncontrol-1. (31) 2 1 2 1
A-- -A- A-- -A- ξ- - - - -1.
3χ 3 3 - 0.5 3
Let us introduce the assumption that with a small
Let's substitute the obtained values into the expressions
increase in deformation energyA-- -A-relationship
(15) and (18).
between energy of elastic and plastic deformations does
not change. Then we write the following expression:
MECHANICAL ENGINEERING

E2J x 1
ρ(z) - -
Alayer-A-ncontrol A layer-n Fl (1 - 0.5)0.5 - 1
-n layer , layer. (32)
A-- -A- A- 3
- F 2l 4 -
(1 - 0.5)20.52-2 - 0.5-1 - 3 - 12--
2
- -1 - -
A-nlayer-A-ncontrol - 36E22Jx2 -
50 -n layer . (33)
A-- -A-
 Table 4

Relative energy distribution of elastic and plastic deformations during contact interaction of various materials

No.

OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

F, kN A, J A layer , J n = A/A Σ
nlayer = A layer
/A Σ
experience control control control

Roll material - M1, workpiece material - M1

12 52.71 3,509 2,553 0.579 0.421

3 72.55 4.37 5,893 0.426 0.574

4 100.13 8,194 13,168 0.384 0.616

5 105.42 7,257 14,986 0.326 0.674

A 106.76 7,189 15,768 0.313 0.687

nlayer -236,992F0.001- 240.202

Roll material - M1, workpiece material - M2

6 18.37 0.509 0.867 0.370 0.630

7 28.29 0.993 2,373 0.295 0.706

8 42.70 1.81 5.139 0.260 0.740

9 57.34 2.365 9,412 0.201 0.799

10 63.52 2,669 15,144 0.15 0.85

eleven 71.17 2,682 20,434 0.116 0.883

B 35.57 1,744 4,533 0.278 0.722

C 71.17 3.851 29,204 0.117 0.884

D 88.96 2.27 24,339 0.085 0.915

npla st-5.605 -10-4F0.594- 0.443

Roll material— M 1, workpiece material - M3

12 6.81 0.176 0.164 0.482 0.518

13 8.27 0.123 0.239 0.340 0.660

14 17.31 0.481 1.952 0.198 0.802

3
nlayer-1.641- 103F1.664-10-4- 1.643 - 10

Roll material - M1, workpiece material - M4

15 10.14 0.225 0.86 0.207 0.793

16 16.19 0.444 2,418 0.155 0.845

17 23.18 0.735 4.825 0.132 0.868

18 30.87 0.892 10.139 0.081 0.919

19 40.39 1,404 20,155 0.049 0.951

20 39.23 1.121 20.774 0.051 0.949

E 16.01 0.457 2.305 0.165 0.835

F 31.14 0.852 9,882 0.079 0.921

G 44.01 0.996 27.06 0.036 0.964

H 44.48 0.771 28,547 0.026 0.974

nlayer -0.003F0.437- 0.601

Roll material - M1, workpiece material - M5

21 2.58 0.838 0.162 0.072 0.928

22 6.06 0.045 0.934 0.046 0.954

23 9.39 0.074 3,029 0.025 0.975

24 13.23 0.053 7,737 0.007 0.993

I 9.79 0.099 4.652 0.021 0.979

npla st-8.558 - 10-4F0.517- 0.878

Roll material - M1, workpiece material - M6

MECHANICAL ENGINEERING

25 0.97 0.004 0.219 0.017 0.983

26 1.13 0.0036 0.471 0.008 0.992

J 0.89 0.0095 0.351 0.026 0.974

nlayer -15,381F0.005- 14,897 51

 The discussion of the results.During production
E2J x.
ρ(z) - 4 cylindrical blanks of large diameter (more than 1.5 m)
Fl using the rolling method, first of all
it is necessary to calculate the technological parameters
EJ2x 1 of the machine. In practice, given the existing dimensions
ρ(z) - -
Fl
OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

0.5(1 - 1 - 0.5) of the rolling drums, it is easiest to change

3 the force of pressing the upper (thrust) roll against the
- F2l4 2-
- -1 - 0.52-0.52- 1 - 3(1 - 1 - 0.5)2- - sheet workpiece to obtain the specified curvature of the
- 36E22Jx2 - workpiece. The work obtained analytical dependences
Simulations that allow one to calculate these efforts
EJ (40) pressing for different thicknesses of sheet metal -
ρ(z) - 42x.
Fl ki taking into account the springing effect. The springing
was taken into account on the basis of the ratio of the
Let's change expression (40). energies of elastic and plastic deformations arising in the
workpiece material during the rolling process.
EJ (41) Conclusions and conclusions.Suggested by the
F-42x.
-(z)l author- Our method for calculating the technological
parameters of rolling sheet blanks of various thicknesses
Let us rewrite expression (39) taking into account (40). allows us to obtain the specified design parameters of
the radius of curvature of the cylindrical shell for the
EJ2 - (1 -nflipper
P )- purpose of further use of welding in the process of
F1-- -4
x
-1 - -. (42)
-(z)l - nlayer - manufacturing the product.

Bibliography
E 2Jx 1
F1-- -4 . (43)
ρ(z)l nlayer 1. Lizin V. T., Pyatkin V. A. Design of thin-walled
ny designs. Moscow: Mechanical Engineering, 1994. 384 p.
To solve equation (43), it is necessary to use the 2. Feodosyev V.I. Resistance of materials. 17th ed.,
results of work [17]. corr. Moscow: Publishing house of MSTU im. N. E. Bauman, 2018. 542 p.

Results of practical research.In ra- Both [17] 3. Timoshenko S.P. Resistance of materials. In 2 vols. Mo-
obtained interpolation characteristics of energy skva: Nauka, 1965.
distribution during the penetration of a hardened steel T. 1. Elementary theory and problems. 1965. 364 p.
ball into various materials. A list of these materials is T. 2. More complex theoretical issues and problems. 1965. 480 p.
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experimental graphs [17], showing the relationship Science, 1976. 608 p.

between the force of penetration of the ball into the 5. Volmir A. S. Stability of deformable systems.
materials under study and the depth of penetration of Moscow: Nauka, 1967. 984 p.
the ball into these materials, data were obtained on the 6. Grigolyuk E. I., Selezneva I. T. Mechanics of solid materials
ratio of the energies of elastic and plastic deformations in formed bodies. In 7 vols. T. 5. Non-classical theories of vibrations of
the contact zone of the ball and the material (Table 4). rods, plates and shells. Moscow: Nauka, 1973. 272 p.
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Let us consider the application of expression (43) parts using bending methods. Moscow: Mechanical Engineering, 1966. 236 p.

using the example of rolling a duralumin workpiece. In 8. Lysov M. I., Sosov N. V. Shaping of parts
table 2 and table. 4, this case is determined by the flexible. Moscow: Mechanical Engineering, 2001. 388 p.
combination of materials M1 and M4. 9. Metal forming handbook // Schuler. Berlin; Heidelberg;
Let us determine the value of the initial rolling force New York; Barcelona; Budapest; Hong Kong; London; Milan; Paris;
from expression (41). Santa Clara; Singapore; Tokyo: Springer, 1998. 573 p.
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EJM4 E MLh
4 3 ESAFORM Bookseries on Material Forming / Ed. D. Banabic. Springer
FM4- 4 x
-4 -
ρ(z)l 12ρ(z)l International Publishing Switzerland, 2016. 416 p. DOI:
10.1007/978-3-319-44070-58.
7.308 -1010- 4 - (0.02)3
- -1039 kN. (44) 11. Krivonos E. V. Study of shell deformation
3 -1.5 - 0.5
with wafer reinforcement during rolling and development of a
method for compensating for shape deviations // Omsk Scientific
According to the table 4 we determine the value of the Bulletin. Ser. Aviation, rocket and power engineering. 2020. Vol. 4, No.
specific energy of plastic deformation. 4. pp. 90–98. DOI: 10.25206/2588-0373-2020-4-4-90-98.

nlayer -0.003F0.437- 0.601 - 12. Krivonos E. V. Justification of the milling scheme

-0.003 - (1039)0.437- 0.601 - 0.663. (45) waffle background // Omsk Scientific Bulletin. Ser. Aviation, missile
and power engineering. 2021. T. 5,
Taking into account expression (43), we obtain: No. 3. pp. 83–90. DOI: 10.25206/2588-0373-2021-5-83-90.
13. Hosford WF, Caddel RM Metall Forming. Mechanics
EMLh 3
1 and Metallurgy. Cambridge University Press, 2007. 328 p. ISBN
F--1-4
4
-
12-(z)l 978-0-511-35453-3.
MECHANICAL ENGINEERING

nlayer
14. Rott O., Hamberg D., Mense C. A comparison of analytical
1
-1039 -1276kN. (46) cutting force models. Preprint. No. 1151. Berlin: WIAS, 2006. 23 p.
0.663
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Thus, depending on the thickness of the workpiece cutting forces to regulate tool life in end milling processes // Precision

52 sheet, it is possible to numerically determine the magnitude Engineering. 2010. Vol. 34, Issue 4. pp. 675–682. DOI: 10.1016/
of the rolling force, taking into account the springing effect. j.precisioneng.2010.05.001.
 16. Pisarenko G.S., Yakovlev A.P., Matveev V.V. Reference AuthorID (RSCI):473365
nick on strength of materials. 2nd ed., revised. and additional Kyiv: ORCID: 0000-0002-7585-433X
Naukova Dumka, 1988. 736 p. Author ID (SCOPUS): 6506002416
17. Chernyavsky D.I., Chernyavsky D.D. Study of di- ResearcherID: N-2038-2015

OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

dynamic characteristics of the impact of two solid deformable bodies Correspondence address: [email protected]
at an impact speed of up to 100 m/s // Omsk Scientific Bulletin. 2021. CHERNYAVSKY Daniel Dmitrievich, student
No. 5 (179). pp. 5–14. DOI: 10.25206/1813-8225-2021-179-5-14. gr. FIT-201 Faculty of Information Technologies and
Computer Systems Omsk State Technical University, Omsk.
18. Bronshtein I. N., Semendyaev K. A. Handbook on ma-
topics for engineers and college students. St. Petersburg: Lan, 2010. For citation
608 p.
Chernyavsky D.I., Chernyavsky D.D. Study of elastic-plastic
bending of sheet blanks of various thicknesses during rolling // Omsk
CHERNYAVSKY Dmitry Ivanovich,doctor of technical of Scientific Bulletin. 2023. No. 2 (186). pp. 44–54. DOI:
Chemical Sciences, Associate Professor (Russia), 10.25206/1813-8225-2023-186-44-54.
Professor of the Department of Mechanical Engineering,
Omsk State Technical University (OmSTU), Omsk. SPIN The article was received by the editor on February
code: 8610-2957 10, 2023. © D. I. Chernyavsky, D. D. Chernyavsky

UDC 629.78 DI CHERNYAVSKY

DOI: 10.25206/1813-8225-2023-186-44-54
DD CHERNYAVSKY

Omsk State
Technical University
Omsk, Russia

STUDY ELASTOPLASTIC BENDING

OF A SHEET BLANK
OF DIFFERENT THICKNESS
WHILE ROLLING
The work analyzes the process of rolling the sheet blank to obtain a cylindrical shell of
large diameter. The analysis is carried out on the basis of strength calculations of
elastoplastic bending of the sheet billet taking into account the springing effect.
Springing calculation is carried out on the basis of available ratios of energy of plastic
and elastic deformations formed in the material of the sheet blank. Conclusions are
drawn and practical recommendations are given, which can be used in the process of
adjustment of process parameters of rolling machines.
Keywords: cylindrical shells, elastic and plastic deformations, radius of curvature, energy
of formation of elastic and plastic deformations, technological parameters of rolling.

References 5. Vol'mir AS Ustoychivost' deformiruyemykh sistem [The

stability of deformable systems]. Moscow, 1967. 984 p. (In Russ.).
1. Lizin VT, Pyatkin VA Proyektirovaniye tonkostennykh 6. Grigolyuk EI, Selezneva IT Mekhanika tverdykh
konstruktsiy [Designing thin-walled constructions]. Moscow, 1994. deformiruyemykh tel. V 7 t. T. 5. Neklassicheskiye teorii kolebaniy
384 p. (In Russ.). sterzhney, plastin i obolochek [Mechanics of Solid Deformable Bodies.
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materials]. 17th ed. Moscow, 2018. 542 p. (In Russ.). and shells]. Moscow, 1973. 272 p. (In Russ.).
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of materials. In 2 vols.]. Moscow, 1965. (In Russ.). detail metodami gibki [Theory and processes of manufacturing parts
MECHANICAL ENGINEERING

Vol. 1. Elementarnaya teoriya i zadachi [Elementary theory and bending methods]. Moscow, 1966. 236 p. (In Russ.).
tasks]. 1965. 364 p. 8. Lysov MI, Sosov NV Formoobrazovaniye details
Vol. 2. Boleye slozhnyye voprosy teorii i zadachi [More complex gibkoy [Forming parts of bending methods]. Moscow, 2001. 388 p. (In
issues of theory and task]. 1965. 480 p. Russ.).
4. Belyayev NM Soprotivleniye materialov [Strength of 9. Metal forming handbook // Schuler. Berlin; Heidelberg;
53
materials]. Moscow, 1976. 608 p. (In Russ.). New York; Barcelona; Budapest; Hong Kong; London; Milan;
 Paris; Santa Clara; Singapore; Tokyo: Springer, 1998. 573 p. (In 17. Chernyavsky D. I., Chernyavsky D. D. Issledovaniye
English). dinamicheskikh kharakteristik udara dvukh tverdykh
10. Multiscale Modeling in Sheet Metal Forming, deformiruyemykh tel pri skorosti udara do 100 m/s [Study
ESAFORM Bookseries on Material Forming / Ed. D. Banabic. Springer of dynamic characteristics of impact of two solid deformable bodies
International Publishing Switzerland, 2016. 416 p. DOI: at impact speed of up to 100 m/s] // Omskiy nauchnyy vestnik.Omsk
OMSK SCIENTIFIC BULLETIN No. 2 (186) 2023

10.1007/978-3-319-44070-58. (In English). Scientific Bulletin.2021. No. 5 (179). P. 5–14. DOI:

11. Krivonos EV Issledovaniye deformatsii obechayki s 10.25206/1813-8225-2021-179-5-14. (In Russ.).
vafel'nym podkrepleniyem pri val'tsevanii i razrabotka metoda 18. Bronshteyn IN, Semendyayev KA Reference
kompensatsii otkloneniy formy [Investigation of deformation of shell po matematike dlya inzhenerov i uchashchikhsya vtuzov [Handbook
with waffle reinforcement during rolling and development of method of mathematics for engineers and university students]. St.
for compensation of deviations forms] // Omskiy nauchnyy vestnik. Petersburg, 2010. 608 p. (In Russ.).
Ser. Aviatsionno-raketnoye i energeticheskoye mashinostroyeniye.
Omsk Scientific Bulletin. Series Aviation-Rocket and Power CHERNYAVSKY Dmitriy Ivanovich,Doctor of
Engineering.2020. Vol. 4, no. 4. P. 90–98. DOI: Technical Sciences, Associate Professor, Professor of
10.25206/2588-0373-2020-4-4-90-98. (In Russ.). Mechanical Engineering Technology Department, Omsk
12. Krivonos EV Obosnovaniye skhemia frezerovaniya State Technical University (OmSTU), Omsk. SPIN code:
vafel'nogo fona [Justification scheme for milling waffle background] // 8610-2957
Omskiy nauchnyy vestnik. Ser. Aviatsionnoraketnoye i AuthorID (RSCI):473365
energeticheskoye mashinostroyeniye.Omsk Scientific Bulletin. Series ORCID: 0000-0002-7585-433X
Aviation-Rocket and Power Engineering.2021. Vol. 5, no. 3. P. 83–90. Author ID (SCOPUS): 6506002416
DOI: 10.25206/2588-0373-2021-5-83-90. (In Russ.). ResearcherID: N-2038-2015
Correspondence address: [email protected]
13. Hosford WF, Caddel RM Metall Forming. Mechanics CHERNYAVSKY Daniil Dmitriyevich,Student gr. FIT-201
and Metallurgy. Cambridge University Press, 2007. 328 p. ISBN of Information Technologies and Computer Systems
978-0-511-35453-3. (In English). Faculty, OmSTU, Omsk.
14. Rott O., Homberg D., Mense C. A comparison of analytical
cutting force models. Preprint. No. 1151. Berlin: WIAS, 2006. 23 p. (In For citations
English).
15. Ibaraki S., Shimizu T. A long-term control scheme of Chernyavsky DI, Chernyavsky DD Study elastoplastic bending of a
cutting forces to regulate tool life in end milling processes // Precision sheet blank of different thickness while rolling // Omsk Scientific
Engineering. 2010. Vol. 34, Issue 4. pp. 675–682. DOI: 10.1016/ Bulletin. 2023. No. 2 (186). P. 44–54. DOI:
j.precisioneng.2010.05.001. (In English). 10.25206/1813-8225-2023-186-44-54.
16. Pisarenko GS, Yakovlev AP, Matveyev VV
Spravochnik po soprotivleniyu materialov [Handbook of Strength of Received February 10, 2023.
Materials]. 2nd ed. Kyiv, 1988. 736 p. (In Russ.). © DI Chernyavsky, DD Chernyavsky
MECHANICAL ENGINEERING

54