Applied Mechanics and Materials Online: 2013-02-13

ISSN: 1662-7482, Vol. 308, pp 179-184

doi:10.4028/www.scientific.net/AMM.308.179
© 2013 Trans Tech Publications, Switzerland

Experimental Determination of the Aluminium Thin Sheets Diameter to a

Sheet Thickness of 1.5 mm for Two-Cylinder Bending Machine

NOVÁKOVÁ Martina
Faculty of Manufacturing Technologies with a seat in Prešov, Štúrova 31, 080 01 Prešov, Slovakia

martina.novakova@tuke.sk

Keywords: Rotary shaping, smallest diameter, alluminium.

Abstract. This paper deals with a thin aluminium sheets experimental rotary shaping with use of
a testing device. The device consists of two rollers. One of them has an elastic surface. From
viewpoint of diagnostics it is necessary to carry out an experiment with defined working conditions
for total rotary shaping of a selected sheet. The aim is to shape a thin sheet made of a selected
material using different values of thickness and to find out the smallest diameter that could be rotary
shaped.

Introduction
One of very important sheet processing technology operations is their shaping. The sheet shape
processing represents one of the most progressive production methods where material changes its
shape due to external forces. Material loss comparing to other production processes is very low.
Thus, rotary shaping is very important maily at flourishing industrial branches production base
modernization, especially at processing industry and machinery. High labour productivity rate can
be achieved by implementation of mechanization and automation.
A relatively new direction in machinery shaping technology aimed at production of sheet
components is a rotary shaping with the use of elastic mediums (RSEM). This method belongs to
cold pressure shaping methods with use of elastic medium created by various kinds of rubber and
polyuretan. [5,6]

RSEM process principle

RSEM is carried out in „open volume“ of an elastic element (Fig. 1) at gradual local effect of
differential force loading on a moving semi-product between the rotating rigid roll (MD) and the
elastic surface roll (FD). [1,2]
An elastic element „open volume“ principle application for sheet shaping reduces shaping
possibilities (field force intensity) of the elastic medium. Despite it, elastic medium local effect
application significantly enables reducing necessary shaping forces and energy demands for
component production. [1,2]
Rotary devices application of thin sheets shaping enables making shaped components larger than
those made on press machines. [5,6]

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180 Operation and Diagnostics of Machines and Production Systems Operational
States

Fig. 1 A component shaping between two rollers. One of them with a surface creating elastic
medium.

Experimental Part
Testing device for thin sheets rotary shaping with the use of elastic mediums. Fig. 2 shows
a testing device which was made in Department of Technological Equipment Design to carry out
thin sheets rotary shaping experimentally [3,9]. The lower roller with diameter of 116 mm is coated
by a polyurethan layer. The upper roller with diameter of 30 mm is made of steel. The ratio of the
two rollers was designed after previous experiments. The aim of them was to determine the
diameter ratio ideal for thin sheets rotary shaping.

Fig. 2 A Testing Device

Rotary Shaping Thin Sheets Design. The following input data were chosen for the
experimental thin sheets rotary shaping:
upper roller diameter Ø 30 mm
upper roller maximal diameter Ø 116 mm
elastic layer hardness 94°ShA or 85°ShA
Material to be shaped:
thin aluminium sheets EN AW 1005 (424005)
Sheets thickness:
0.5 mm / 1.0 mm / 1.2 mm / 1.5 mm / 2.0 mm
Shaped sheets width related to elastic mediums rollers
50 mm
90 mm
 Applied Mechanics and Materials Vol. 308 181

For a specific radius of a shaped sheet in elastic mediums, necessary depth of impress according to
[3,4] is minimally 4 mm. That is a reason why this information during rotary shaping will be
verified.

Fig. 3 Samples cut out for testing

Rotary shaped sheet diameter experimental determination. At this experiment, the sheets
made of the same material and of the same width are compared. At the first experiment sheets with
50 mm of width were rotary shaped. In the same time a rotary shape impress depth was determined.
Fig 4 shows a relation between impress depth and rotary shaped sheet diameter. The impress depth
was determined after previous experiments. Sheets of width from 0,5 mm to 1,5 mm were shaped. 5
samples of each thickness were shaped. As the graph shows, the smallest diameter of the 0.5 mm
sheet was cca 34 mm. For thicker sheets shaping a deeper impress is needed. At the impress depth
less than 4 mm it was impossible to shape the 1 mm and 1.2 mm thick sheets. It is can be said that
the sheet diameter is lowered linearly with impress depth increasing.

Fig. 4 Relation between rotary shaped sheet diameter and impress depth. Sheet width is 50 mm.
182 Operation and Diagnostics of Machines and Production Systems Operational
States

Fig. 5 Rotary shaped aluminium sheets. Sheet width 50 mm

In the next experiment sheets made of the same material were rotary shaped with width 90 mm.
Fig 6 represents a relation between rotary shaped sheet diameter and impress depth. Sheets of
thickness from 0.5 mm to 1,5 mm were shaped as well. 5 samples of each thickness were shaped.
The graph shows that the smallest diameter was 35 mm with sheet thickness of 0.5 mm. At all
samples the smallest impress depth was determined cca 4 mm at the width of 90 mm. This is the
difference comparing to previous experiments results with width of 50 mm. Using this width, small
differences are visible (see Fig 6) from point of view of rotary shaping linearity related to sheet
width. The diamaters vary from 33 mm (the biggest possible impress depth) to 39 mm. Despite it, it
can be also said that the rotary shaped sheet diameter is lowered in relation to impress depth.

Fig. 6 Relation between rotary shaped sheet diameter and impress depth. Sheet width is 90 mm.

Fig. 7 Rotary shaped aluminium sheets. Sheet width 90 mm

 Applied Mechanics and Materials Vol. 308 183

Table 1 gives experiment results (Fig 4) and (Fig 6) of aluminium sheets rotary shaping. Chart 1
shows conditions of the experiments and for which the assessed graphic relations are valid. The
chart is divided into parts for material parameters (thickness and width of material) and working
parameters. As far the working parameters, which are theoretically processed in [7] [9], impress
depth in relation with impress force was studied. The result of the experiments is the smallest
impress diameter for respective impress depth. In the same time, impress depth value at which
rotary shaping is impossible, is given in the chart. Having taken experiment results into account, it
can be said that the smallest impress depth for possible total rotary shaping at width of 50 mm as
well as 90 mm is minimal 3.9 mm. If the impress depth is less than 3.9 mm, total rotary shaping is
impossible, as given in Chart 1.
Table 1 Results of impress depth and rotary shaping diameters
Results of impress depth and rotary shaping diameters
0,5 1 1,2 1,5
Rotary shaping

Rotary shaping

Rotary shaping

Rotary shaping
Impress depth

Impress depth

Impress depth

Impress depth
diameter

diameter

diameter

diameter
width/thickess

3,8 not 3,8 – not 3,8 not 3,8 not

finished 4,3 finished finished finished
3,95 36,19 4,35 36,05 4,21 36,98 4,21 36,11
50 mm 4,19 35,53 4,45 35,88 4,4 36,12 4,42 35,61
4,35 34,97 4,59 35,36 4,59 35,55 4,59 35,21
4,45 34,55 4,6 34,98 4,6 35,24 4,65 34,4
4,6 34,26 4,68 34,45 4,65 34,82 4,7 34,2
3,8 not 3,8 not 3,8 not 3,8 not
finished finished finished finished
3,92 35,21 3,92 35,25 3,92 36,6 3,92 38,2
90 mm 4,2 34,5 4,2 34,95 4,2 35,55 4,2 37,25
4,35 34,35 4,35 34,5 4,35 35,5 4,35 37,1
4,45 34,1 4,45 34,4 4,45 34,4 4,45 35,18
4,58 33,8 4,58 34,38 4,58 34,3 4,58 34,98

Summary
The aim of the paper was to perform rotary shaping of thin sheets with use of the testing device and
to determine the relation between rotary shaped sheet diameter and impress depth. At the same time,
the aim was also to form as the smallest diameter as possible by rotary shaping under conditions
stated in the laboratory. As it can be seen in the experimental part, the aluminium sheet with
diameter less than 40 mm can be rotary shaped. These results are contribution not only for scientific
purposes but also for practice. It is necessary to shape also sheets made of other kinds of material
and to determine further relations. The rotary shaping with the use of elastic mediums is a modern,
relatively new and highly effective technology, which is in the time of the financial crisis very
important. The use of RSEM strong points, which does not damage contact surface of semi-
products, allows to achieve economically advantageous production technology and highly efficient
machine device.
184 Operation and Diagnostics of Machines and Production Systems Operational
States

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