Analysis of the levelling process based upon an analytic forming model

Abstract Roller levelling is a complex forming process to minimize flatness imperfections and residual stresses by repeated forming of a sheet. At the Institute for Metal Forming and Metal Forming Machine Tools at the University of Hanover an analytic forming model is being developed which analyses the levelling process with sufficient precision in a shorter time than is possible with the finite element method (FEM). With this analytic forming model, the states of multiple forming under bending conditions during the levelling process can be investigated. The residual stresses and the residual bend of the sheet metal are calculated. Additionally, the forces acting on the rollers during levelling are determined. The controlling system assures setting of rollers automatically.