Analytical forming forces in two roller flow forming

Abstract

This paper presents a comprehensive model for calculating forming forces in two-roller flow forming using the upper-bound method. The model incorporates roller design parameters such as tip radius and attack angle, accurately defining the contact surface and including all relevant forming parameters. Experimental validation on a WF VUD 600 vertical former demonstrates the model’s predictive capability, with force measurements compared to theoretical values. Statistical analyses indicate strong correlations between predicted and actual forces, highlighting the model’s effectiveness.