Analytical model of flat rolling force for corrugated composite sheet

 Analytical model of flat rolling force for corrugated composite sheet


Understanding the Rolling Force in Corrugated Composite Sheets: An Analytical Approach

The manufacturing industry continues to evolve toward lightweight, high-strength, and multifunctional materials—especially in automotive, aerospace, and construction sectors. One such class of materials gaining traction is corrugated composite sheets, which combine high stiffness with reduced weight due to their structural geometry.

A key challenge in processing these materials is the accurate prediction and control of rolling forces during the flat rolling process. Rolling is one of the most cost-effective and widely used metal forming techniques. However, when dealing with non-flat geometries like corrugation and multi-material laminates, traditional rolling models fall short.

Our recent research addresses this gap by developing a comprehensive analytical model to predict the flat rolling force for corrugated composite sheets. This model accounts for:

✅ Geometrical effects of the corrugation (amplitude and wavelength)
✅ Mechanical properties of each composite layer (elastic modulus, yield strength, Poisson’s ratio)
✅ Contact mechanics between rolls and the sheet
✅ Frictional forces and material hardening behavior

Unlike finite element simulations which are computationally intensive, our analytical model provides a faster, cost-efficient solution suitable for integration into real-time process control systems.

🔍 Why Corrugated Composites?

Corrugation significantly enhances the flexural rigidity of thin sheets while maintaining low weight. When combined with high-performance composites—like fiber-reinforced polymers or metal-polymer laminates—these materials serve well in energy absorption, impact resistance, and insulation.

But their non-uniform thickness and mechanical anisotropy pose challenges during rolling. If not modeled accurately, defects like wrinkling, delamination, or incomplete deformation can occur, compromising both structural and aesthetic quality.

🧠 Key Outcomes of Our Analytical Study:

  • 📉 Reduction in experimental trial-and-error: By predicting rolling force requirements, manufacturers can pre-set optimal process parameters.

  • ⚙️ Enhanced material control: Better control over thickness distribution and surface quality.

  • 🕒 Time & cost savings: A faster alternative to numerical simulations without compromising accuracy.

  • 📈 Scalability: The model can be adapted for various corrugated geometries and material combinations.

🛠️ Applications:

  • 🚗 Automotive lightweight body panels

  • 🛫 Aerospace interior structures

  • 🏗️ Architectural panels and cladding

  • ⚙️ Industrial heat exchangers

  • 🚀 Satellite enclosures

This work bridges a crucial gap between material science, mechanical engineering, and manufacturing technology, offering a tool for both researchers and industry professionals aiming to innovate in advanced forming processes.

We welcome collaborations from researchers, industry experts, and materials engineers to further develop and validate this model across different scales and materials.

Global Particle Physics Excellence Awards


#Sciencefather 
#FlatRolling 
#CompositeMaterials 
#CorrugatedSheet 
#RollingForce 
#AnalyticalModel 
#MechanicalEngineering 
#MaterialScience 
#AdvancedManufacturing 
#EngineeringResearch 
#SheetMetalForming 
#DeformationMechanics

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