A three-dimensional finite element model for the roll bending of heavy plates using a 4-roll plate bending machine

Roll bending is a manufacturing process in which sheet metal is continuously formed into a round shape with the help of typically three or four rotating rolls. It is used in particular for the production of thick-walled pipes and shells with large volumes, which are used in the maritime sector, in pipeline construction and in the field of renewable energies. In these areas, at the current state of the art, the process is mainly controlled manually. However, the control of the process is of great importance for its efficiency. For example, over-controlling the machine leads to over-bending of the plate and thus often to material waste, whereas under-bending requires additional rolling passes and leads to an increase in production time. To reduce the human influence on the economic efficiency of the process and to objectify the process, research is currently being carried out on the development of automation solutions for roll bending.