Abstract: The forming principle of three-dimensional surface by flexible rolling and the control methods of two kind of typical surface forming are illustrated. The stress and strain states of the deformation zone are analyzed. The deformations and their relationship in the three principle directions are also analyzed. The forming process of two typical surfaces are simulated using finite element method. Simulation results show that the positive and negative spreads appear respectively when saddle and convex surfaces are formed. No matter of convex surface or saddle surface, the larger the relative elongation of longitudinal fibers is, and larger longitudinal deformation is. The flexible rolling forming experiments are conducted. The measurement and analysis results show that, compared with the target value, the maximum forming error is no more than 3.2 mm. Therefore, the quality of the forming surface is good and the springback is small.

Key words: material synthesis and processing technology, flexible rolling, three-dimensional surface, deformation analysis, forming simulation