Development of a flexible roll forming machine for cutting curved parts with virtual prototyping technology

Predicting machine tool performance at the design stage is one way to resolve the time issue and achieve cost savings. Our objective in the present work was to develop a new roll forming machine for curved products comprising a servo motor, ball screw, and rolling-element linear guide, with the support of virtual prototyping technology. First, a multibody simulation model was developed based upon the machine concept to investigate machine dynamic behavior in real time. Then, we proposed an adaptive sliding-mode PID-based controller (ASMPID) to control the manufacturing process. We performed co-simulation between the mechanical structure and the virtual controller to investigate the head unit trajectory and to identify optimal control parameters. Finally, we manufactured a prototype machine to evaluate the machine accuracy and the benefits of the new system. The results indicated that the proposed model including the mechanical structure and the intelligent controller was effective and feasible for designing the roll forming machine. We expect this work to improve the prototyping efficiency of new rolling machines.