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Known bend and curl forces often are not so important for the process because
very often, the maximum force of the press machine is greater than the
bending or curling force. However, knowing the magnitude of these forces is
necessary for a definition of the blank-holder forces. Because of the
phenomenon of material fatigue of the blank springs, these forces need to be
30 to 50 percent greater than the bending or the curling forces.

5.4.5 Three-Roll Forming

For bending differently shaped cylinders (plain round, corrugated round,

flattened, elliptical, etc.) or truncated cones of sheet metal, the three-roll
forming process is used. Depending upon such variables as the composition of
the work metal, machine capability, or part size, the shape may be formed in a
single pass or a series of passes. Fig. 5.12 illustrates the basic setup for threeroll forming on pyramid-type machines. The two lower rolls on pyramid-type
machines are driven, and the adjustable top roll serves as an idler and is rotated
by friction with the workpiece.

Fig. 5.12 Three- roll bending.

In most set-ups, short curved sections of circular work are performed on the
ends of the metal workpiece in a press brake or on a hydraulic press.
Otherwise, the workpieces would have ends that, instead of being curved,
would be straight. In the process described above, the radius of the bend
allowance is much greater than the material thickness of the workpiece; under
these conditions, the bending is entirely in the elastic-plastic domain.

To achieve permanent deformation in the outer and inner fibers of the material,
the following relationship must apply:

(5.11)
Otherwise, the workpiece, instead of being curved, will be straight after
unloading. The bending force on the upper roll is given by the formula:

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Thomas Industrial Library

(5.12)
where:
D = outer diameter of the workpiece,
b = length of bend,
T = material thickness,
YS = yield stress,
E = modulus of elasticity, and
u = bend angle.

The bend angle can be calculated from the geometric ratio in Fig. 5.12 and is
given by the formula:

where:
l v = distance between lower rolls, and
d = lower rolls diameter.

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