1999 Continuous Four-Roll Plate Bending

International Journal of Machine Tools & Manufacture 39 (1999) 905–935
Continuous four-roll plate bending: a production process for

the manufacture of single seamed tubes of large and
medium diameters
M. Huaa,*, K. Bainesb, I.M. Colec
a
Department of Manufacturing Engineering and Engineering Management, City University of Hong Kong, 83 Tat
Chee Avenue, Kowloon Tong, Kowloon, Hong Kong
b
Department of Mechanical Engineering, Adelaide University, Adelaide, Australia
c
Department of Electrical and Mechanical Engineering, Aston University, Aston Triangle, Birmingham, UK
Received 11 August 1998
Abstract
Continuous roller bending of plates is an effective process in the production of single seamed tubes of
large and medium diameters. The process is capable of a wide range of various tube diameters from the
smallest of just larger than the diameter of the top roller to the largest limited only by the handling capacity
of the bender. It requires less investment in toolings compared to other bending processes. Relevant rese-
arches on roller-bending are reviewed and referred to. Current roller-bending machines are discussed. In
particular, the versatility of the four-roll bender and its ability to generate better circularity, thereby helping
to reduce material wastage and amount of subsequent machining, are examined. This paper discusses not
only the design considerations, but also the working principles and some relevant bending mechanisms of
the process.  1999 Elsevier Science Ltd. All rights reserved.
1. Introduction
Large and medium sized tubes and tubular sections are extensively used in many engineering
artifacts and structures. They also form the major skeleton of oil and gas rigs, the construction
* Corresponding author. Tel.: (0852) 27888 443; Fax: (0852) 27888 423; e-mail: memnghua@cityu.edu.hk
0890-6955/99/$ - see front matter  1999 Elsevier Science Ltd. All rights reserved.
PII: S 0 8 9 0 - 6 9 5 5 ( 9 8 ) 0 0 0 7 5 - 3
906 M. Hua et al. / International Journal of Machine Tools & Manufacture 39 (1999) 905–935
of tunnels, commercial and industrial buildings. In the metal bending industry, the production of
large and medium sized tubular sections is normally carried out by, firstly, bending the sheets or
plates to circular sections using stamp-bending and/or stretch-bending processes etc., and then,
welding them to form a larger seamed sector or cylinder. Existing sheet and plate bending tech-
niques are: stamp-bending, stretch-bending, press-braking etc. Due to elastic recovery, and the
physical geometry and bending principles of these bending processes, there often remains a con-
siderable length of straight end-sections that need to be machined off, thus incurring a relatively
higher material wastage and production cost. Furthermore, any particular tool setting of the above
processes generally limits bend-radii to a narrow range and additional toolings and/or machines
are required to complete the production process. The continuous roller bending process, which
can be used to bend sheets and plates to a large range of bend-radii, with their smallest one just
larger than the radius of the top roll of the roller bender, and the largest one as large as the shop-
floor capable of handling, minimises these shortcomings.
The roller bending process usually produces higher dimensional accuracy of the finished pro-
ducts. Its continuous operational feature effectively reduces the number of seams on the finished
products. Consequently single seamed tubular sections can be produced. Additionally, these roller
bending machines only occupy a relatively small space on the shop-floor, when compared with
other bending machines capable of bending similar range of plates and sheets.
The advantages, of the continuous roller bending process, over the other plate and sheet bending
processes have led to various bender geometries being designed and constructed [1,2]. Although
the three-roll pyramid configuration is the most common configuration, different configurations
of four-roll benders, and even two-roll benders [3], are also employed in industry. The existing
three- or four-roll benders may have horizontal or vertical rollers with symmetrical or asymmetri-
cal configurations. Depending upon the capacity of a bender, the rollers may be either driven
by manual, or hydraulic-mechanical, electromechanical, wholly hydraulic power, or driven by a
combination of manual and electromechanical power. Each particular design or configuration
seeks to perform a specific operation or achieve a certain process advantage. The three-roll pyra-
mid bender is accommodated within a rigid frame, its design rating is thus higher and can be
utilised to bend thicker plates. The four-roll bender was developed to shorten further the straight
end-edges which often remain on the bendplates or bendsheets of single-seam tubes formed by
the three-roll bending process. The four-roll benders improves material handling and productivity,
and offers greater flexibility. They are also able to operate in any of the three-roll configuration.
Although there are many types of roller benders available for the plate and sheet bending
industry, the normal practice of plate roller bending still heavily depends upon the experience
and the skill of the operator. Working to templates, or by trial and error, yet remains as a common
practice in industry. For this reason, most plate bending manufacturers experience low productivity
and are not able to make full use of their available equipment.
To exploit more fully the potential of roller benders especially for large and medium sized
tubular sections requires a sound understanding of their operational process. Thus a general study
was undertaken to analyse the mechanics of roller bending with particular attention to continuous
four-roll bending operation.
M. Hua et al. / International Journal of Machine Tools & Manufacture 39 (1999) 905–935 907
2. Relevant researches on roller plate bending
Although the first roller bender was designed and constructed almost a century ago [2], aca-
demic and industrial research work on the plate bending process is still in its infancy. There is
only little literature concerning the roller plate and sheet bending process available.
Although Winship [2], in 1983, described most of the different types of three- and four-roll
benders and their operation, he did not provide any detailed insight of the bending mechanism.
Roggerdorf and Haeusler [1] traced the evolution of a three-roll symmetrical pyramid bender
produced in 1948 by Dornach in Switzerland. They described the development and evolution of
various Haeusler bending machines during the period of 1948 to 1979 providing an insight into
the development of industrial roller benders.
Provided that the bender capacity is not exceeded, the bending failure of a plate is a function
of its formability limit (if the mechanics of the process is still within the limit of bender designed
capacity). Bata and Malik [4] studied the effects of material tensile stress and UTS, impact and
surface hardness values relating these factors to the plate formability. Through their investigation
of the symmetrical elongation of the plates, Bata and Malik concluded that thick steel plate could
be roll formed to strain levels > 5%, i.e. ranging between 7–9.4%. Bata and Malik also found
that the stress relieving treatment lowered the yield strength and UTS of the roll formed plates
and in some cases restored these properties to those of the “as-received” plates. Some theoretical
analyses of three-roll pyramid bending were produced by Bassett and Johnson [5] and Hansen
and Jannerup [6]. Bassett and Johnson [5] analysed the top roll vertical force Ftv and torque T
required in the three-roll pyramid bending process by: (a) a geometrical analysis assuming that
the deflection of the plate is in the arc of a circle; and (b) a load analysis using a uni-axial stress–
strain relationship for the material. Their results on bending aluminium alloy indicated that their
geometrical analysis predicted the upper roll vertical force and the torque to an acceptable level
of accuracy when only the tensile stress strain properties of the material was considered. The
study of Bassett and Johnson concluded that other parameters, such as the distance between the
upper and lower rolls, etc., required either the introduction of a constant factor or further work.
Furthermore, the analysis was only applicable to single pass steady continuous bending mode.
Hansen and Jannerup [6] also modelled the single pass elastic–plastic bending of a beam using
three-roll pyramid bender. They commenced with a geometrical analysis and assumed a triangular
moment distribution between the rollers. They also considered the stress–strain relationship of
the actual material. The geometrical analysis of Hansen and Jannerup accounted for the offset of
the contact point of the plate and the upper roll from the vertical centre line of the roll. The
model also computed the bending force and bending moment. Experimental measurements and
theoretical results calculated using the model for the special case of constant curvature [6] showed
good agreement.
Though the analyses of both Bassett and Johnson [5] and Hansen and Jannerup [6] seemed to
produce theoretical results in agreement with experimental measurements, they only deal with
one specific three-roll bender and a particular single pass steady continuous bending mode. In
general, the change in the geometrical set-up and drive arrangements of the benders always
changes the bending mechanics of the process. Furthermore, the validity of certain assumptions,
such as negligible friction etc., may require further investigation to justify.
The above review illustrates that only limited studies are available on the continuous three-roll
bending of plates. A detailed analysis on the forces and torques, for either single or multipass
bending mode, in four-roll benders has apparently not been carried out. Sansome [7] initiated a
research programme in this particular area in 1982. In that study the process of continuous four-
roll bending of plates for both single and multipass bending operations for different modes was
initiated. Hua et al. [7–10] subsequently split the whole process into: (1) pre-bending operation;
and (2) continuous bending operation with (i) the pre-bending active side roll operative mode,
and (ii) the pre-bending inactive side roll operative mode. They first analysed the plate internal
bending resistance at the top roll contact, for both single pass and multipass bending processes.
Their research considered: (a) the geometry boundary conditions incorporating the solution of the
biharmonic equation for the deflection of (i) thin and initially flat plate and (ii) thin and initially
curved plate; and (b) the force and moment equilibrium equations. Hua et al. [8] also formulated
a mathematical model for determining the mechanics of the four-roll bending of thin plates. The
plate internal bending resistance, at top roll contact, was modelled for elastic–elastoplastic defor-
mation. They evaluated theoretically (i) the plate internal bending resistance, (ii) the springback
curvature, (iii) the distance of elastic interface from plate central plane, and (iv) the local instan-
taneous bend radius at the top roll contact, for producing an anticipated finished bend radius in
bending plates of various thicknesses and widths. This study also led to an experimental model
bender to be designed and constructed [10].
Although the design of the model bender was initially aimed at simulating a four-roll bender
at a U.K. company, its flexibility also provided a means to investigate experimentally the bending
mechanics of various three- and four-roll plate and sheet bending process, by suitable adjustment
of the roller geometry. This allowed the optimal operating conditions to be exploited experimen-
tally. Furthering the design specifications of the model bender, Hua, Baines and Cole [9] generated
a mathematical analysis for quantifying experimentally the plate springback, at the top roll contact,
for a particular model bender configuration and its supplementary instrumentation.
The study by Hua [7] expounded on some of the process mechanisms in the continuous four
roll plate bending. Experimental studies [11] in bending of HP30 aluminium plates were later
performed. Both experimental and theoretical results indicated that the overall bending power
needed to effect an anticipated finished bend radius through a multipass route is higher than that
necessary in the single pass bending mode. The higher power consumption for the multipass
bending mode resulted from work lost in the elastic recovery, after the release of the bending
load on the rollers, for each individual bending pass.
3. Working principle and bending sequence
3.1. General configuration and working principle of four-roll bender
Fig. 1 shows the perspective configuration of the operational rolls and bendplate of a four-roll
bender. In the figure, xyz is a coordinate system for the bendplate while XYZ is the coordinates
specifically relative to the bender. Generally, a bendplate which is either: (1) at its initially geo-
metrical condition before bending, or (2) being bent in a roller bender, is to be bent to an antici-
pated bend radius defined upon the release of bending load on the roller. For some four-roll
benders the vertical movement of the top roll Ot is restrained. In most cases, the top roll is
Fig. 1. Perspective configuration of a four-roll plate bender with a flat plate.
normally the driver and thus provides transfer of the bendplate, especially for the continuous
bending operation. In most four-roll benders, the other three rolls, i.e. the two side rolls and the
bottom pinch roll, are free to rotate, but are powered to move along their respective positional
plane. The gripping of a bendplate can be performed by moving the axis of the bottom roll centre
towards that of the top roll.
The plate in Fig. 1 is assumed to be initially flat before bending proceeds. The positional plane
of either the pre-bending active (hereafter named pre-active) or the pre-bending inactive (hereafter
named pre-inactive) side roll powering direction, depends upon the design setting of ⫺ X0 and
X0. It also depends upon the inclination of the respective positional powering angles ⫺ ␺ and ␺
for pre-inactive and pre-active side roll, respectively. The design settings ⫺ X0 and X0 are the
respective distances of the pre-inactive and pre-active side roll centres to the vertical plane through
the centres of both the top and bottom pinch rolls, i.e. ObOOt. For a four-roll bender, setting the
positional powering centre, Op, is the interception line of the vertical plane through ObOOt and
the positional plane through AA of the operative side roll (Fig. 2). It is normally constant for a
particular bender geometry setting. The instantaneous contact angle ␪s between the instantaneous
contact plane, of bendplate and bending active side roll, through Os⬘CsOi varies when the active
side roll floats upwards. Given a particular four-roll bender, with the top pinch roll driven to
rotate both clockwises and anticlockwises, the nomination of the pre-bending active or inactive
side roll is generally arbitrary unless specific bendplate handling features are pre-fixed to the
bender. In general, this is dependent on whichever side roll is to perform the pre-bending task.
The r.h.s. side roll, as shown in Figs. 1 and 2, is arbitrarily nominated to pre-bend the plate or
sheet. Subsequently, it will be called the pre-active side roll whilst the l.h.s. side roll the pre-
inactive side roll.
Fig. 2. Pre-bending of plate for a set of positional powering angle ␺.

3.2. Four-roll bending sequences
Figs. 3 and 4 show the detailed operational sequences for thin and thick plate four-roll bendings.
They consist of some or all of the following bending modes:
1. edge setting preparation mode (procedure 1 in Fig. 3 for thin plate bending; procedures 1, 2,
4, 5 and 6 in Fig. 4 for thick plate bending),
2. edge pre-bending mode (procedure 2, or procedure between 3 and 4, in Fig. 3 for thin plate
bending; procedures 3 and 7 in Fig. 4 for thick plate bending),
3. pre-bending continuous bending mode (procedure 4 in Fig. 3 for thin plate bending; procedures
between 3 and 4, and between 7 and 8 in Fig. 4 for thick plate bending)
4. roller swapping bending mode (procedure between 3 and 4 in Fig. 3 for thin plate bending)
5. steady continuous bending mode (procedures 5 and 6 in Fig. 3 for thin plate bending; procedure
8 in Fig. 4 for thick plate bending) and
6. completion rolling bending mode (procedure 6 in Fig. 3 for thin plate bending; procedure 8
in Fig. 4 for thick plate bending).
In thin plate bending operation, normally, the procedures in Fig. 3 are followed. The combination
of the bending modes depends primarily upon the material flexural rigidity, the bender capacity,
and partly upon the size and the required accuracy of a finished tubular section. It is, sometimes,
influenced by the personal preference of the operators.
Fig. 3. Operational sequence for thin plate bending process.

Fig. 4. Operational sequence for thick plate bending process.
From a general comparison between the thin and the thick plate operations (Figs. 3 and 4), it
can be seen that the particular differences are: (a) a further pre-bending operation to prepare the
finished end is needed for the thick plate bending mode, i.e. procedures 3–7 in Fig. 4; (b) a steady
continuous bending mode of thin plate bending can be carried out with either the pre-active side
roll operative (i.e. procedure 3 in Fig. 3) or with the pre-inactive side roll in operative (i.e.
procedure 5 in Fig. 3)—either operation requires the pre-inactive side roll to complete the bending
process; (c) a steady continuous bending for thick plate operation is generally performed with
both pre-active and pre-inactive side rolls in operation (i.e. procedure 8 in Fig. 4). For most
purposes both side rolls are in operation to optimise the bending effect by altering the top roll
contact in the steady-continuous bending mode for thick plate operation. An appropriate pos-
itioning combination of the two side rolls optimises the bending mechanics on the rolls.
3.3. Individual bending sequence
In most continuous four-roll bending practice, the edge setting preparation mode allows the
bendplate or sheet to be correctly aligned in the pinch rolls. This prevents twisting and edge
distortion of the plate in the bending process. It thus produces a nearly perfect tubular. Both the
edge pre-bending mode and the pre-bending continuous bending mode produce uniform circular
end-section with sufficient length to bridge over the distance of either ⫺ X0 or X0 in Fig. 1 for
further continuous bending with the pre-inactive side roll operative. The benefit of these two
bending modes is to reduce the straight-edge ends of a bendplate. This consequently reduces
material wastage, machining time and cost in comparison with tubular sections bent by the more
traditional techniques discussed previously. When continuous bending mode is performed by the
pre-active side roll, the latter of the two bending modes is not required. In this case, after the
pre-bending mode, the roller swapping bending mode is used, followed by the completion of the
rolling bending mode with pre-inactive side roll in action. The roller-exchange-bending-operation
(procedures 3–4 in Fig. 3 and procedures 7–8 in Fig. 4) forms part of the continuous bending
stage. This operation is normally performed to correct the springback of a bendplate. The region
of elastic recovery is controlled by the effective deformed zone (hereafter is termed EDZ) between
the plate inlet to the pre-active side roll and the pinch region at the top roll contact, i.e. CbCtCaCs
in Fig. 5, as a result of the elastic recovery when the pre-active side roll is released. The next
operation is one of the steady continuous bending with the pre-inactive side roll operative (Fig.
Fig. 5. Boundary conditions for steady-continuous bending with pre-active side roll operative.
6). This completes the bending of the tubular section to a uniform radius. With a set position of
the active side roll, the roller bending mode is completed (procedure 6 in Fig. 3 and procedure
8 in Fig. 4). This corrects any non-circularity of the sections bent by the previous transient bend-
ings of (a) the pre-bending continuous and (b) the roller swapping continuous stages. This helps
to improve further the dimensional accuracy of the bendplate.
Fig. 6. Deformation and boundary conditions for steady-continuous with pre-inactive side roll operative.
4. Significance of roll pinch in bending process
4.1. Roll pinch and surface friction in bendplate conveyance
In most metal forming processes, such as tube and wire drawing and press-brake bending etc.,
contact friction is detrimental. It increases the working load and power required to accomplish a
particular finishing shape of product. Successful continuous roller plate bending can only be
ensured if there is initially sufficient friction in the pinch region to prevent slippage of the bend-
plate in the pinch gap, especially relevant in the resistance of the bendplate when translating from
and through the pinch for the pre-bending operation. Generally, the friction between the sliding
surfaces is a function of the surface texture and lubrication condition of the rollers and the bend-
plate, and the magnitude of the required pinch force. It also depends upon the surface contact area.
For a particular magnitude of pinch force and surface roughness of the bendplate and lubri-
cation, the value of friction resisting the sliding of the bendplate is constant. To increase the
friction force, it is necessary to adjust the axis of the bottom pinch roll closer to that of the top
roll. This obviously increases the elastic indentation of the pinch rolls on to the top and bottom
surfaces of the bendplate, and subsequently enlarges the surface contact areas. In order to avoid
plastic indentation on the bendplate surface, the pinch forces should always be below the yield
limit of the bendplate material. In the actual roller bending operation, particular attention must
be paid to the complex strain and stress fields in the pinch contact when pre-bending mode is
being initiated by the active side roll. Theoretically, the estimation of the respective surface contact
area on either side of the bendplate and the stress distribution in the contact region should enable
the pinch force on the top and the bottom pinch roll, and thus the contact friction force, to be
determined. Furthermore, acknowledging that the EDZ is between the contacts of the active side
roll and the pinch region, an estimate can be made of the required torque and power. However,
the floating movement and the variation of the roll–plate contact of the active bending side roll
complicates the analysis of the combined stress field in the pinch contact region. Understanding
the friction effect and quantifying these variances will lead to better design that allows the four-
roll bending process to operate more effectively.
The contact friction and pinch load not only oppose the sliding of the plate in the pinch, they
also convey the bendplate through the pinch gap in: (a) the edge setting preparation mode, (b)
the continuous bending modes, and (c) the completion rolling bending mode (Figs. 3 and 4).
Effective conveyance of the bendplate can only be accomplished if there is no slip between the
pinch rolls and the bendplate. Clearly, the pinch and contact friction required for (a) and (c) are
relatively smaller compared with that of (b). It should be noted that too high a friction, as a
consequence of high pinch forces, will proportionally increase the driving torque and power. A
suitable compromise is therefore required.
Although high surface roughness of a bendplate increases the friction, it can also produce stress
concentration that may subsequently lead to material fracture and bending failure. Surface rough-
ness becomes more critical in the roller bending of a very tight bend radius in single pass bending.
If the friction is viewed as the tearing shear of interactive asperities [12] in the contact region,
then in a series of multipass bendings with a relatively small step of each incremental bend, an
improvement in the smoothness of the bendplate surface will be experienced.
At the pinch contact, the local combined stress should be at or less than the material elastic
limit. This will prevent plastic indentation of the contact surface. It is suggested that an effective
pinch can be obtained by increasing the pinch surface contact area for a specific force magnitude,
thus implying that smoother contact surfaces and larger pinch roll radii are needed. However, the
latter will limit the size of the minimum diameter of the bendplate. It also restricts the movement
of active side roll along its positional powering plane, thus imposing further restrictions in mini-
mum plate bend radius.
Depending upon whether the steady continuous bending operation is with (i) pre-active side
roll operative (Fig. 5) or (ii) pre-inactive side roll operative (Fig. 6), the side roll–plate contact
friction may be either detrimental or beneficial to the bending process when slippage occurs. In
Fig. 5, the roll–plate contact friction at Cs opposes the overhanging part CsB of the bendplate, as
it moves into the effective deformation zone CbCtCaCs. It thus causes a stretching effect in the
deformed zone between Ct and Ca. This reduces the magnitude of the bend radii in the zone and,
subsequently, a higher roll position and a higher bending force on the pre-active side roll are
required to achieve an anticipated bent radius. For the pre-inactive bending mode (Fig. 6), the
roll–plate contact friction at Cs⬙ resists the exiting of the deformed bendplate beyond the contact.
This increases slightly the bendplate curvature in the effective deformation section Ca⬘Ct⬘. How-
ever, the contact friction on the active side roll for both operations in slipping condition contributes
a proportion of torque to the drive in transporting the bendplate through the pinch roll gap.
4.2. Variation of the plate–roll contacts and effect on bending mechanics
For all bending operational modes, the effective contact bending forces Ft, Fb, Fs on the top,
the bottom and the active side roll (see Fig. 7), respectively, are the resultant vectors of their
respective horizontal Fi( ⫽ t,b,s)h and the vertical Fi( ⫽ t,b,s)v components at their corresponding con-
tact points Ct, Cb, Cs respectively (e.g. the resultant vector of Fsh and Fsv for the pre-active side
roll in Fig. 7 is Fs), between the bendplate and the rolls. When the operative side roll is powered
upward, respective contact angle of the plate–rolls varies accordingly which, in turn, changes the
bending arms of individual bending force components on each roller. This subsequently alters
their respective resultant bending forces on the rollers.
Interfacial friction between plate and roller influences the vector of the resultant bending forces
applied by each roll. When friction is negligible, the resultant bending force, at the roll–plate
contacts, on each roll may normally be perpendicular to the local surface profile of the bendplate
(Figs. 5–7) [6]. Under the frictional condition, the vectors of both contacts and resultant bending
forces change according to the direction of friction force between the roll–plate interfaces. Gener-
ally, the resultant vector of the applied bending force is no-longer perpendicular to the local
surface of a bendplate when friction occurs in the contact interface between the bendplate and
rollers. The interfacial friction tends to move both Cs and the resultant force Fs of Fsv and Fsh
towards the Y-axis in pre-bending mode (Fig. 2). In steady-continuous bending with pre-active
side roll operative as shown in Fig. 5, both (i) Ct and Ft, and (ii) Cs and Fs tend to move away
from the Y-axis towards the inlet of the bendplate. In steady-continuous bending with pre-inactive
side roll operative as shown in Fig. 6, both (i) Cs⬙ and Fs⬘, and (ii) Ct⬘ and Ft⬘ tend to move
towards where closer to the Y-axis whilst Cb⬘ and Fb⬘ to be moved away from the Y-axis towards
the plate inlet.
Fig. 7. Active side roll operative mode.

4.3. Contact between active side roll and plate at pre-bending stage
Fig. 2 shows an initially flat bendplate (the dash-lined bendplate along OX) gripped in the pinch
region, here the roll–plate contact on the top surface Cs⬘ of the pre-active side roll is located at
a distance X0 away from the vertical plane ObOOtOp through the central axes of the top and the
bottom roller. At this particular instant, the effective external bending moment is the product of
its instantaneous vertical force component Fsv⬘, the bending moment arm of X0 and an instan-
taneous contact angle having zero inclination with the vertical plane AOs⬘Cs⬘A, which is parallel
to ObOOtOp. As further bending is initiated, the pre-active side roll floats upwardly along its
positional powering plane EOs⬘Op, and the instantaneous contact line Cs moves anticlockwise
from the top surface of the active side roll as ␪s increases. Consequently, the horizontal bending
arm for Fsv reduces as its vertical counterpart for Fsh increases.
Fig. 8 shows three typical instantaneous conditions of the side roll contact angle ␪s which varies
as bending proceeds and also differs in relation to the variation of:
1. the radius of the finished bendplate,
2. the magnitude of the initial arm X0 of the bending moment for the initial vertical force compo-
nent Fsv at the top rim of the pre-active side roll (Fig. 7), and
3. the positional powering direction and angle ␺ of the side roll.
—Within the capacity of the bender ␺ may be in the range of 0° to 180° if the bender has
sufficient capacity.
Fig. 8. Three typical conditions of side roll contact angle ␪s.

Normally, the maximum contact angle ␪sm occurs at the position where the movement of the
operative side roll is restricted by the top roll.
In Fig. 7 Xs and Xt are the instantaneously horizontal contact distances from the vertical plane
of ObOOtOp of the pre-active side roll and the top roll, respectively, with the bendplate, and Ys
and Yt are the corresponding vertical distances from the contacts to the axial plane OX of the
initially flat plate. Thus the effective external bending moment, Me about the top roll contact, is
the resultant of the bending load components on the operative side roll and is therefore expressed
(Fig. 7) as:
Me ⫽ Fsh兩Ys ⫺ Yt兩 ⫹ Fsv兩Xs ⫺ Xt兩 (1)
Let Fsr be the resultant applying bending force along the positional powering direction, which is
in a set powering angle ␺, of the active side roll whilst Fs be its counterpart acting at and along
the direction of the instantaneous roller–plate contact angle ␪s (Fig. 7), Fs can therefore be
expressed as Fs ⫽ Fsr cos ␤ in which ␤ is the angle between Fsr and Fs, and has value of (i) ␤
⫽ ␺ ⫺ ␪s when ␺ > ␪s, (ii) ␤ ⫽ 0 when ␺ ⫽ ␪s, and (iii) ␤ ⫽ ␪ ⫺ ␺ when ␺ ⬍ ␪s (Fig. 8).
Subsequently, Eq. (1) can be further expressed in term of Fsr as [7]:
Me ⫽ Fsr cos ␤[兩Ys ⫺ Yt兩sin ␪s ⫹ 兩Xs ⫺ Xt兩 cos ␪s]. (2)
As shown in Fig. 7, the co-ordinates of initial centre Os⬘ of the active side roll, at the instant of
the operative side roll starting to bend an initially flat bendplate, are (X0, ⫺ rs ⫺ h) in which rs,
h, are the side roll radius and the half thickness of the bendplate respectively. Geometrical analysis
gives the equation of the positional powering plane EOs⬘Op, along which it is located with the
instantaneous centre Os(Xsi, Ysi) of the active side roll, as:
Ysi ⫽ cot ␺(X0 ⫺ Xsi) ⫺ rs ⫺ h. (3)
In this case, h is half the bendplate thickness and rs is the radius of the operative side roll.
Subsequently, the instantaneous contact (Xs, Ys) of the operative side roll can be related to (Xsi,
Ysi) as:
Ys ⫽ Ysi ⫹ rs cos ␪s (4a)
Xs ⫽ Xsi ⫺ rs sin ␪s. (4b)
The above analysis indicates that for a given top roll contact (Xt, Yt), the effectiveness of the
bending due to the horizontal force component Fsh, at the operative side roll contact, increases
as the bending increases (as the result of increasing its bending moment arm |Ys ⫺ Yt|), whilst
that due to the vertical force component Fsv decreases [as the result of decreasing its bending
moment arm |Xs ⫺ Xt|—this is also confirmed by Eq. (1)] for continuous upward movement of
the operative side roll after initiation of bending. Eq. (4) shows that the effectiveness of the vertical
contact force component Fsv is reduced when the instantaneous contact angle ␪s, is increased. It
also shows that its maximum effectiveness is at ␪s ⫽ 0 because it gives a maximum Xs. Eq. (3)
indicates that the smaller is the positional powering angle ␺ the greater the increasing rate of Ysi,
and subsequently the higher is the effectiveness of Fsh the more achievable the bending action.
Eq. (2) suggests that the applied bending force resultant Fs in the positional powering direction
will be fully utilised when the positional powering angle ␺ and the instantaneous contact angle
␪s are equal, i.e. the condition of ␺ ⫽ ␪s [Fig. 8(ii)]. It also indicates that the deviation of ␪s
away from ␪s ⫽ ␺ will reduce the magnitude of its effective resultant vector at roll contact.
However, in the actual roller bending process, the top roll contact also varies as the bending
proceeds. The analysis explains of the complex effect on the bending mechanics due to the
geometry setting of the four-roll bender and the variation of the operative side roll contact.
4.4. Plate–roll contacts between the top and bottom rolls in pre-bending
Due to the increase of the plate curvature in the effective deformation zone, between the operat-
ive side roll contact and the pinch region towards the top roll contact (Fig. 7), there is a reduction
in the effective bending arms, i.e. |Ys ⫺ Yt| and |Xs ⫺ Xt|, of the bending moment in Eqs. (1) and
(2). This will then diminish the bending effect of the applied bending force Fs. Thus the absolute
magnitude of Fs has to be increased in order to achieve the same anticipated bend radius. Gener-
ally, variation of the contacts at the top and the operative side roll will also alter the corresponding
contact at the bottom roll. If the applied load on the bottom roll is assumed constant, the equilib-
rium condition of the external bending moments about the top roll contact will impart a downward
movement of the bottom roll. The bottom roll therefore also shifts its contact Cb downstream
from the initial plane ObOOtOp (Fig. 7). Otherwise, substantial increment of the pinch load on
the bottom roll may be experienced.
4.5. Plate–roll contacts in steady continuous bending
If the steady continuous bending mode is performed with the pre-active side roll operative, the
contacts of the rollers and the plate will usually be as they are at the final stage of the pre-bending
mode, while their counterpart with the pre-inactive side roll operative will be those at the final
stage of the suitably adjusted roll-swapping operation. There is a difference in boundary local
bend radii for individual contacts between the two steady continuous bending modes, for example,
the boundary local bend radius at the plate–roll contact for (a) the operative side roll, (b) the top
roll, and (c) the bottom roll, being:
1. infinity, EIrf/(EI ⫹ Mirf), and rf, respectively, in bending an initially flat plate to an anticipated
bend radius of rf in single/first pass with pre-active side roll operative (Fig. 5),
2. rf, EIrf/(EI ⫹ Mirf), and infinity, respectively, in bending an initially flat plate to an anticipated
bend radius of rf in single/first pass with pre-inactive side roll operative (Fig. 6),
3. rf, EIrff/(EI ⫹ Mirff), and rff, respectively, in bending an initially curved plate of bend radius
rf to an anticipated radius of rff, i.e. second/subsequent pass, with pre-active side roll operat-
ive, and
4. rff, EIrff/(EI ⫹ Mirff), and rf, respectively, in bending an initially curved plate of bend radius
rf to an anticipated radius of rff, i.e. second/subsequently pass, with pre-inactive side roll operat-
ive,
in which E, I and Mi are respectively, the Young’s modulus, the second moment of inertia, and
the internal bending resistance of bending moment at the top roll contact of the bendplate. Because
of this difference, the position of operative side roll in the pre-inactive operation mode is normally
higher, thus experiencing higher bend load, than in the pre-active operation mode (Fig. 6). In
addition, the contact between bendplate and top roll is shifted downstream closer to operative
side roll, and that between bendplate and bottom roll is shifted upstream further away from the
operative side when pre-inactive side roll is in operation (Fig. 6). Generally speaking, the initial
geometry and the anticipated finishing bend radius of a bendplate affect the individual position
of plate–roll contacts and subsequently alter the magnitude and combination of bending arms of
the corresponding bending force components; they tend to magnify the effectiveness of horizontal
bending force component which is the prime factor in bending tight finished bend radius in the
bending operation.
5. Effect of overhanging plate section inlet to pre-active side roll
In bending a very long bendplate using the bender with horizontal bend axis, the weight of the
overhanging bendplate before the inlet to the pre-active side roll may generate a counter-bending
moment WgLg (Fig. 9). The counter-bending moment reduces the effective curvature in the EDZ
Fig. 9. The production of counter-bending moment.

CsCaCtCbCs. It therefore increases the bending force on the operative side roll. This is mainly due
to the following reasons:
(a) The counter-bending moment reduces the effective plate curvatures along the effective
deformation zone, between the operative side roll and the top roll contacts. It therefore
decreases the penetration length of the plastic deformation zone within EDZ.
—Its existence usually alters the distribution of the external bending moment along the EDZ.
Technically, the counter-bending moment beyond the operative side roll may superimpose the
bending moment before top roll contact and generate a bending moment diagram as shown
in Fig. 10. It therefore significantly diminishes the magnitude of the effective internal bending
moment in EDZ, created by the identical bending load on the operative side roll when the
counter-bending moment is not present.
(b) The counter-bending moment generates negative curvature near the operative side roll. It
may also produce a large surface contact band. Consequently it magnifies the friction effect
against the plate transportation in the continuous bending mode, if the operative side roll is
not completely free to rotate. It thus further smoothens the curvature in the EDZ and increases
the driving torque on the top pinch roll.
Fig. 10. Effect of counter-bending moment on the bending moment distribution in the EDZ.
(c) The counter-bending moment tends to stretch the plate section in the EDZ against the
bending direction. It thus changes the stress and strain distribution across the plate thickness
as shown in Fig. 11. The shifting of the neutral axis towards the bent plate concave surface
indicates that the tensile strain on the convex side increases. This may subsequently cause a
thinning effect.
(d) The stretching effect tends to pull the bendplate out from the pinch region. To counter it
a higher pinch pressure is required. This results in higher pinch forces on both pinch rolls.
Normally, the magnitude of the counter-bending moment is a direct function of the dimensions
and density of the bendplate. However, its magnitude diminishes as the pre-bending proceeds.
This is due to the upward movement of the operative side roll tipping up the bendplate, thus
shortening the counter-bending moment arm Lg.
In the steady continuous bending mode (Fig. 9), the overhanging bendplate gradually reduces
in length as the bendplate is transferred through the pinch gap. Consequently, the counter-bending
moment of the overhanging section is continuously decreasing owing to the reduction of its effec-
tive weight and bending moment arm. For example, the reduction of the section DCC⬘D⬘ moves
its centre of gravity (CG) to CG⬘ with corresponding counter-bending moment arms of Lg and
Lg⬘ in a bending duration ⌬t. Generally, Wg > Wg⬘ and Lg > Lg⬘, therefore WgLg > Wg⬘Lg⬘.
6. Deformation nature of bend plate

Whichever bending mode is performed, the maximum plastic deformation of the bendplate
generally occurs in the contact region between the top roll and the bendplate. This indicates that
Fig. 11. Effect of counter-bending moment on stress–strain distribution in the EDZ.

the radius of curvature of the bendplate in the effective deformation zone, between the contacts
of the top and the operative side rolls, gradually decreases as the bendplate is conveyed from the
active side roll contact to the top pinch roll contact. The deformation nature of a bendplate in
the EDZ will be dependent upon which side roll is in operative for the steady continuous sheet
and plate bending mode.
6.1. Thin plate bending during pre-active side roll operative
In steady-continuous bending mode with pre-active side roll operative, plate material at CaCs
(Fig. 12) entering the contact Cs of the pre-active side roll, where the radius of curvature is
assuming an infinitive value, will be transported toward and then out from the pinch plane OY.
The plate material initially at CaCs will firstly be elastically deformed until reaching PiPo where
plastic yield firstly occurs on the outer fibre layer Pi and Po, respectively, of the plate. In this
entry region CaCsPoPi, i.e. zone Et (Fig. 12), the deformation is completely elastic. When the top
roll is being continuously driven, the material which has been initially at CaCs is being transported
further from the first yield line PiPo to the pinch roll in the region PiPoCbCt (Fig. 12) and it is
experiencing elastic–plastic deformation. Within such elastic–plastic deformation region, there
may exist an elastic core Ec (Fig. 12) which is sandwiched by two elastoplastic deformation bands.
Fig. 12. A deformation zone of plate in steady-continuous bending mode.

The depth of the elastoplastic deformation increases when the material at PiPo, which has initially
been at CaCs, is moving towards the pinch.
Let (i) A0a0b0B0, (ii) A1a1b1B1 and (iii) A2a2b2B2 be the three equally spaced cross sections,
when a certain amount of plastic deformation occurs, of a bendplate in the EDZ (Fig. 12), the
difference in the plastic deformation depths Dt1 and Dt2, at A1B1 and A2B2 with respect to A0B0
and A1B1, is thus:
Dt1 ⫽ (A1a1 ⫹ b1B1) ⫺ (A0a0 ⫹ b0B0) (5a)
and
Dt2 ⫽ (A2a2 ⫹ b2B2) ⫺ (A1a1 ⫹ b1B1) (5b)
respectively. Under the condition of constant transporting velocity of the plate, A0B0 will occupy
the place of A1B1, while A1B1 will occupy that of A2B2 and so on. The successive increment of
the plastic deformation depth A0B0, as the bendplate moves towards the pinch, can adequately be
represented by the expressions (5a) and (5b), and its general expression for the increment of
plastic depth Dti at AiBi relating to Ai−1Bi−1 is thus:
DTi ⫽ [(Aiai ⫹ biBi) ⫺ (Ai ⫺ 1ai ⫺ 1 ⫹ bi ⫺ 1Bi ⫺ 1)]. (6)
Since the sum of the infinitesimal plastic depth dDT, at any cross section from the instant of first
yield to the pinch, must be equal to the plastic depth at the pinch, the total progressive plastic
deformation DT can be defined in terms of its infinitesimal values as:
冕
Dp
冘
n
DT ⫽ DTi ⫽ dDT ⫽ The plastic depth Dp at the pinch. (7)

i⫽1
0
When a plate is bent in the steady continuous bending mode, its radius Rt of curvature is minimum
at the top roll contact Ct and approximately equal to Rt ⫽ rfEI/(EI ⫹ Mrf) (Fig. 5). Beyond Ct
and between CtCb, the radius of curvature of the bendplate will gradually be spunback to rf, at
Cb, when it is transported from Ct to Cb. Depending upon the magnitude of rf, there may exist a
complete yield region at or adjacent to the pinch region which may extend to the exit from the
bottom roll contact Cb.
6.2. Thin plate bending during pre-inactive side roll operative
A deformation zone for steady continuous bending of a bendplate with the pre-inactive side
roll operative is shown in Fig. 6. This shows that the maximum plastic deformation also occurs
at the pinch roll contact line Ct⬘. Instead of a progressively increasing deformation, the defor-
mation before Ca⬘Cs⬙ and past the top roll contact Ct⬙ is influenced by the progressive springback
of the bendplate, as it is being transported from the contact of the top pinch roll to the pre-inactive
side roll. Therefore, the final position of the pre-inactive side roll in pre-bending is higher than
that of the pre-active side roll in order to accomplish uniform curvature of the bendplate.
6.3. Thick bendplate bending during both side rolls operative
To bend a thick bendplate, both pre-active side rolls are operative for the steady continuous
mode (procedure 8, Fig. 4). It thus has the combined effect of the last two cases for thin plate
bending. Consequently it makes the nature of contact more complex. Generally, the unique fea-
tures of the effective deformation zone, are where; (i) the bendplate is progressively deformed,
at inlet to the pinch, and (ii) the bendplate is gradually sprungback at exit from the pinch. These
and the various combinations of the two side roll positions change the roll contact. Thus a specific
bend radius may be achieved by suitably positioning the two operative side rolls.
For the operation where the two side rolls are symmetrically positioned about the pinch rolls,
in the steady continuous state bending, its mechanism may be considered similar to bending a
bendplate in a symmetrical three-roll bender.
7. Experimental indication and prediction
7.1. Experimental set-up
To study the mechanics of four-roll plate bending process, a four-roll model bender (Fig. 13)
with the individual ends of its top roll mounted into each respective cross-beam was specifically
designed and built at Aston University [7]. Fig. 14 illustrates the location of load-cells and torque-
meters. The load-cells were so designed so that they measured the axial and normal force-compo-
nents on the individual cylinders of the two side rolls and the bottom pinch roll. The horizontal
and vertical force-components on the top roll were measured by the four load-cells situated at
the edges of the two cross-beams. At the driven end of the top roll, there was a torque-meter
connecting with the prop-shaft of a speed variator for measuring its driving torque during bending
operation. Each loadcell measured the axial force, Fa, and bending force, Fb. The signal from
each loadcell was converted to a force quantity by using the appropriate calibration equations
Fj=a,b ⫽ 9966.96(a0 ⫹ b0x) N in which a0 and b0 were the calibration constants which varied
with different sensing components and bridges, x was the u.v. chart reading in mm. The resultant
force, F, on each roll was determined by:
冘冘
n n
F ⫽ [( Fai)2 ⫹ ( Fbi)2]1/2 (8)

i⫽1 i⫽1
where, n ⫽ 2 for the bottom pinch roll and each of the side rolls; n ⫽ 4 for the top roll.
The mean torque, Tmean, and the maximum torque, Tmax, were both measured by torquemeter
(see Fig. 14). The mean torque Tmean was evaluated from the difference on the trace of u.v. chart
between the mean value Tr and the initially set reference chart value T0, as the continuously steady
state was reached, i.e.
Tmean ⫽ a(Tr ⫺ T0) ⫹ b (9)
where a and b were the calibration constants; Tr and T0 were the measured chart width of the
trace in mm.
Fig. 13. Model bender.
The maximum torque was defined as the highest torque experienced in each continuous bending
mode. It was evaluated by replacing the reference quantities of Tmean and Tr by Tmax and Ti,
respectively, in Eq. (9) above.
Fig. 14. Arrangement of the sensing components in the model bender.
7.2. Torque characteristics on top roll
The pre-bending torque (Fig. 15) on the top roll steadily increases with tighter finished bend
radius in bending HP30 aluminium plate of 8.1 mm thickness ⫻ 80.5 mm width. The pre-bending
torque on the top roll measured suggests the existence of a tangential force Fsh which is transmitted
to the pinch region and subsequently to the top roll. It also indicates that the reversely driven top
roll in pre-bending may reduce the overall resultant pinch force (although this may be difficult
to control).
Due to the fact that a higher position of the operative side roll is required to achieve the
anticipated rf, which leads to an increase in the contact angle ␪s⬘ (Fig. 6) between the plate and
the pre-inactive side roll, the applied torque on the top roll, in the pre-continuous (i.e. roll
swapping) bending with the inactive side roll operative, thus shows a trend of higher values than
those of the pre-bending operation. The bender geometry is such that it may also give a higher
value of the effective horizontal force component Fsr⬘ cos ␤⬘ (see Eq. (2), in which ␤⬘ is the angle
between the resultant force Fs⬘ and the actually applying bending force Fsr⬘ in the direction of
Os⵮Op—Fig. 6) as a consequence of increasing the contact angle ␪s⬘. The variation of the top roll
Fig. 15. Experimental torque on top roll for a single pass bending.
contact alters the loading nature of Fsr⬘ cos ␤⬘ relative to the top roll itself which, in addition to
the effect of the relative rigidity of the plate, gives a characteristic of steadily decreasing torque
with tighter rf. Both maximum and mean torques on the top roll for the steady continuous bending,
with the pre-active side roll operative, increase steadily with smaller rf (Fig. 15). However the
curve for the former has a convex shape while that for the latter has a concave shape. It is
observed that a wider spacing between them at high values of rf and the spacing becomes narrower
as rf decreases. The corresponding curves for that of steady continuous bending with pre-inactive
side roll operative also show a concave shape for both torques and a convergent trend at lower
rf (Fig. 15). Comparing the shape of the curves for either maximum or mean torque of both pre-
active and pre-inactive side roll bending modes, it can be seen that the value of torque for the
latter bending mode commences with a higher one (at high rf) and finishes at lower value (at
smaller rf) than the former operation mode.
These characteristics are probably resulted from the alteration of the loading conditions relative
to the top roll, and from the changes in the nature of plate–roll contacts and plate deformation,
during bending.
7.3. Bending force characteristics
It is observed from Fig. 16 that the bending forces, for either pre-bending or pre-active side
roll operative conditions, in bending the 8.1 mm thick ⫻ 80.5 mm wide HP30 aluminium plates,
gradually increases as the finished inner radius rf decreases. The curves indicate that the bending
force on the operative side roll varies with the bending operational modes, i.e. (i) pre-bending
Fig. 16. Bending force characteristics for a single pass bending.
and (ii) steady continuous bending for (a) pre-active side roll and (b) pre-inactive side roll oper-
ation (SRO). The trace shows that for a particular plate dimension, continuous bending gives
slightly lower forces on the side roll relative to the pre-bending mode. It also shows that the force
experienced in the pre-inactive side roll bending condition is relatively higher than in the pre-
bending condition. The above characteristics are theoretically possible as a result of the different
anticipated boundary conditions because of the different plate geometry of the bender. This sub-
sequently alters the contacts of the bendplate and the rollers. It, in turn, changes the value of the
bending arms (i.e. ⌬Xst, ⌬Xtb, ⌬Yst and ⌬Ytb where ⌬Xst ⫽ xs ⫺ xt and so on) and the effective
force components (Fsv, Fsh, Ftv, Fth, Fbv and Fbh). The change of the geometrical boundary con-
ditions generally leads to a different deformation distribution in the EDZs. The distinguishable
forms of deformation for each of the three operation modes are as follows:
(a) In pre-bending, the deformation zones between the operative side roll and the top roll
contacts, and between the top and bottom roll contacts are progressively deformed.
(b) In the steady continuous bending, with the pre-active side roll operative, the plate between
the top and bottom roll contacts is progressively sprungback, and between the operative side
roll and top roll contacts the plate is progressively deformed. Furthermore, a certain longitudi-
nal length of the plate in the latter zone has been deformed in the pre-bending mode prior to
the resumption of continuous bending.
(c) In the steady continuous bending with the pre-inactive side roll operative, the plate in
between the top and bottom roll contacts is progressively deformed while that in between the
operative side roll and the top roll contacts is progressively sprungback.
The deformation mechanism which occurs in operation mode (a) generally requires a higher bend-
ing force on the roll than that in operation mode (b). Due to the physical constraint of the bottom
roll position during bending, the initially flat geometry of the plate as it enters the pinch region,
and also the deformation nature in (c), it is necessary to shift the top roll contact downstream
towards the pre-inactive side roll so as to achieve the finished bend radius rf and also to extend
the effective bending arms ⌬Ytb and ⌬Xtb of the bending force on the bottom roll. Furthermore,
the pre-inactive side roll needs to be positioned higher. The latter leads to shorter bending arms
⌬Yst and ⌬Xst of the bending force components on the side roll. These subsequently give rise to
higher bending force required by the particular bending mode. The above mechanisms generally
take place in both single and multipass bending [7].
The characteristics in Fig. 16 suggests that in bending the 80.5 mm wide plates, both the top
and bottom rolls experience similar loading characteristics. The bending force firstly increases to
a maximum value at a certain value of rf and then gradually decreases.
The higher bending force on the rollers for the steady-continuous bending mode with pre-
inactive side roll operative, in comparison with that for pre-bending mode, indicates that the
former’s bending force may be a determining factor for the actual bender capacity.
It is observed from Fig. 16 that the measured force on the top roll is lower than on the bottom
roll. This contradicts the expected results. Generally, it was expected that the top roll would exert
a higher force than the bottom roll. Initially, it was thought that these results were due to the fact
that the top roll load cells were mounted so as to give a “portal frame” structure within the
bending unit (Fig. 13) of the model bender. The additive vertical force components from the
operative side roll and the bottom roll would thus generate twisting moments. These induced
twisting moments would oppose and cancel the expected bending signal, thus affecting the accu-
racy of the measured load on the top roll. In order to verify the validity of this assumption, an
estimation of the magnitude of induced twisting moments was carried out with a load of 150 kN
vertically applied at the mid-span of each top beam. This, in total, gave a maximum induced
bending force on the top loadcells within an estimated 12% of the total applied load. Fig. 16
indicates that the top roll bending force is 34% lower than that of the bottom roll at rfi ⫽ 711
mm, for single pass bending of 8 mm thick ⫻ 80 mm wide HP30 aluminium plates. This is at
least 20% different from the estimated value of 12% (if we take into account the side roll bending
force, the difference would be even higher than 20%). Consequently the above result seems to
suggest that the observed characteristics for the top roll could be an inherent bending mechanism,
most likely due to the rigidity of the power system of bottom pinch roll, of the process. However,
further verification and proper understanding of this mechanism are needed.
7.4. Distance of elastic–elastoplastic interface from plate neutral plane at top roll contact
In an elastic–elastoplastic analysis [8], the distance of elastic–elastoplastic interface Ci from

the neutral plane of a bendplate at the top roll contact for a local bend radius R was determined by:
(1 ⫺ ␯2)R␴0
Ci ⫽ (10)
E√1 ⫺ ␯ ⫹ ␯2
where ␯ is Poisson ratio, and ␴0 is the yield stress of the plate material. To determine Ci, value
of R corresponding to an anticipated bend radius rf must be firstly iterated by:
1 1 Mi
⫽ ⫺ (11)
rf R EI
in which the internal bending resistance Mi through the bendplate (having width b, and material
workhardening constant H and workhardening index n) at top roll contact was formulated [8] as:
Mi ⫽ b兵兰 ␴xz dz ⫹ 兰 ␴xz dz其 ⫽ b(A ⫹ B) (12)
elastic elastoplastic
where,
2R2(1 ⫺ ␯2)2␴30
A⫽ ; (13a)
3E2(1 ⫺ ␯ ⫹ ␯2)3/2
B ⫽ 2R2
冦 2HK 2⌬⑀3n
3√3
1
⫹
(n ⫹ 1)HK⌬⑀2n
2n ⫹ 1
1
⫹1
⫹
K(K␴0 ⫹ Hg)⌬⑀2n
√3
1
⫹
√3H⌬⑀1n ⫹ 2
4(n ⫹ 2)
(13b)
冉
⫹ K␴ 0 ⫹
Hg
n⫹1 冊
⌬⑀n1 ⫹ 1 ⫹
2K␴0g⌬⑀n1 √3␴0⌬⑀21
√3
⫹
4
⫹ g ␴ 0 ⌬⑀ 1 ;
冧
K⫽
H
E 冤 3(1 ⫺ ␯)
2√(1 ⫺ ␯ ⫹ ␯ )
2
⫺
√3
2
;
冥 (13c)
(1 ⫺ ␯2)␴0
g⫽ . (13d)
E√(1 ⫺ ␯ ⫹ ␯2)
⌬⑀1 is the upper integral limit of the second integral term of Eq. (12) which was determined by
numerically iterating z/R ⫽ (√3⌬⑀)/2 ⫹ K⌬⑀n ⫹ g for an assumed known R (which is initially
equal to the estimated bend radius Ry when first plastic yield occurs on the outer fibre of the plate
in the EDZ) and z ⫽ half thickness of the bendplate [8]. Then A, B and Mi for the corresponding R
and ⌬⑀1 are estimated. If Eq. (11) is not satisfied, infinitesimal reduction in R is made, the corre-
sponding ⌬⑀1 is once again iterated and new A, B and Mi are determined. The procedures are
repetitively performed until Eq. (11) meets an allowable accuracy. Finally Ci is calculated. By
such iterations, a theoretical prediction was made for single/first pass bending of 80.5 mm wide
HP30 aluminium plates: with thicknesses of 8.1 mm, 10.2 mm, 12.07 mm and 14.68 mm; and
having average mechanical properties of ␯ ⫽ 0.34, ␴0 ⫽ 215 N/mm2, H ⫽ 580.68 N/mm2, E ⫽
67.19 kN/mm2 and n ⫽ 0.364.
Fig. 17 shows the graphical representation of the theoretically predicted characteristics of the
distance of the elastic–elastoplastic deformation interface Ci from the neutral plane of the plate
at the top roll contact, relative to the plate finished bend radius rf. It can be observed that the
curves for the four plate thicknesses tend to converge, from large rf towards a small rf. This
indicates that the rate of the elastic–elastoplastic deformation interface 兩dci/drf兩 penetrating towards
the neutral plane of the plate at the top roll contact, is greater for the thicker plate specimens
than for the thinner ones. It can also be observed from the graphs that all the curves for the
different plate thickness almost overlap with each other when rf is approximately equal to 80
mm. The overlapping and the converging of the curves from Ci suggest that the effective plastic
deformation rate through the plate thickness at the contact is relatively higher for the thicker plate
than for the thinner ones. This subsequently suppresses the springback more effectively. However
the deformation nature of a particular plate is always related to its material properties.
8. Further design studies
Research reported in [7–10] has only provided some rudimentary concepts of certain aspects of
the mechanics of the four-roll bending process. Undoubtedly, further experimental and theoretical
Fig. 17. Distance of plate elastic–elastoplastic interface from central plane in single pass bending of 80.5 mm wide
HP30 aluminium plate specimens.
investigations of the subject are necessary in order to understand fully this bending process. This
further knowledge will lead to a better exploitation of the bending process in the future. Some
areas of investigation are as follows.
8.1. Roller size and roller combination
The roller size determines the area of contact between the roller and bendplate. It affects the
magnitude of the contact friction and the effective bendplate curvatures in the deformation zone,
between the operative side roll contacts and the pinch region. However, this may confine the
roller movement and thus restrict the minimum diameter of a bendplate that can be produced.
Also, it increases the magnitude of the required driving torque. Different combinations and sizes
of rollers should allow various bending features to be exploited and optimised.
8.2. Roller drives
Generally the top roll is driven in the traditional four-roll benders. The addition of drives to
the other rollers may generate slipping at the contact areas and thus vary the strain field in the
deformation zone. Quantification of this effect on the bending mechanism would assist future
four-roll bender design.
8.3. Optimisation of geometrical setting for X0 and ␺
Large values of X0 normally improve the effectiveness of the bending force on the active
operative side roll, they also restrict of the minimum finished bend-radius and increases the circu-
larity of the bendplate achieved in a ‘one-go’ continuous bending mode. This is because a longer
length of end-section is needed to bridge over X0 in the pre-bending steady continuous and the
end-completion bending modes. Thus suitable combination of X0 and ␺ and settings may be
optimised through an appropriate experimental and theoretical study.
8.4. Surface roughness of bendplate
Surface roughness assists to optimise the pinch load by controlling the retrieval and sliding of
the plate in the pinch region during the pre-bending mode. However, it is detrimental to the steady
continuous and pre-bending operational modes since a stretching effect occurs in the EDZ. This
reduces the effective bend radii of bendplate in the zone. Quantification of these effects is also
helpful to the effective operation of the roller sheet–plate bending process.
It is believed that carrying out the above studies, possibly in cooperation with industry, will
extend further the understanding of the continuous roller sheet–plate bending process.
References
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[6] N.E. Hansen, O. Jannerup, ASME Paper No. 78WA/Prod 6 (1979).
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[8] M. Hua, K. Baines, D.H. Sansome, Int Conf on Computational Plasticity, Spain (1987).
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[10] M. Hua, K. Baines, D.H. Sansome, Proc. 2nd UK National Conf on Prod Research, Edinburgh (1986).
[11] M. Hua, K. Baines, I.M. Cole, J Mater Process Technol 48 (1995) 159–172.
[12] D. Tabor, Proc R Soc Series A 251 (1959) 378–393.

1999 Continuous Four-Roll Plate Bending

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1999 Continuous Four-Roll Plate Bending

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International Journal of Machine Tools & Manufacture 39 (1999) 905–935

Continuous four-roll plate bending: a production process for

2. Relevant researches on roller plate bending

3. Working principle and bending sequence

3.1. General configuration and working principle of four-roll bender

Fig. 1. Perspective configuration of a four-roll plate bender with a flat plate.

Fig. 2. Pre-bending of plate for a set of positional powering angle ␺.

3.2. Four-roll bending sequences

Fig. 3. Operational sequence for thin plate bending process.

Fig. 4. Operational sequence for thick plate bending process.

3.3. Individual bending sequence

4. Significance of roll pinch in bending process

4.1. Roll pinch and surface friction in bendplate conveyance

4.2. Variation of the plate–roll contacts and effect on bending mechanics

Fig. 7. Active side roll operative mode.

Fig. 8. Three typical conditions of side roll contact angle ␪s.

4.5. Plate–roll contacts in steady continuous bending

5. Effect of overhanging plate section inlet to pre-active side roll

Fig. 9. The production of counter-bending moment.

6. Deformation nature of bend plate

Fig. 11. Effect of counter-bending moment on stress–strain distribution in the EDZ.

6.1. Thin plate bending during pre-active side roll operative

Fig. 12. A deformation zone of plate in steady-continuous bending mode.

DT ⫽ DTi ⫽ dDT ⫽ The plastic depth Dp at the pinch. (7)

6.2. Thin plate bending during pre-inactive side roll operative

6.3. Thick bendplate bending during both side rolls operative

7. Experimental indication and prediction

7.1. Experimental set-up

F ⫽ [( Fai)2 ⫹ ( Fbi)2]1/2 (8)

Fig. 13. Model bender.

Fig. 14. Arrangement of the sensing components in the model bender.

7.2. Torque characteristics on top roll

7.3. Bending force characteristics

Fig. 16. Bending force characteristics for a single pass bending.

In an elastic–elastoplastic analysis [8], the distance of elastic–elastoplastic interface Ci from

8. Further design studies

8.1. Roller size and roller combination

8.2. Roller drives

8.3. Optimisation of geometrical setting for X0 and ␺

8.4. Surface roughness of bendplate

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