https://nevonprojects.com/manual-roller-bending-machine/
I definitely think the video will help a lot as it shows how the machine operates.
What I need is calculations on how the system works as a whole.
This includes : equations on how the rollers are used to bend metal.
Gear equations (aka) gear ratios
FEA analysis
Stress strain and von misses
Any other calculations you feel are necessary needed to cover all the bases when it comes to bending metal and roller bending machines.
Can you also provide an analysis of the results obtained through modelling by using software like ANSYS or any other types of software that provide stress and strain results
I also provided a sample report that seems to be based off a roller bending machine like the one in the link provided above.
General design principles (This is just a sample of the calculations I found off the internet which is similar to my design)
Following basic shearing operation on a sheet metal, components can be rolled to give it a definite shape. Bending of parts depends upon material properties at the location of the bend. To achieve bending, the work material must be subjected to two major forces; frictional force which causes a no slip action when metal and roller came in contact and a bending force acting against the forward speed and the torque applied to move the material.
Where,
a = distance from exit zone to the no-slip point (assume a = L/2);
F = force applied to rollers;
T = torque applied to rollers;
L = roll gap;
r = radius of rollers;
μ = frictional force 0.4 Nm-1;
ho, hf = thickness of the sheet before and after time t.
At least two rollers are involved in flat rolling depending on the thickness and properties of material while three or multiple roller system is required in shape rolling. A work material under bending load is subjected to some form of residual stress and deformation as it bends. Materials at the outer bend radius undergo tensile plastic deformation while the material at the inner bend radius undergoes compressive plastic deformation.