輥式冷彎成型是以金屬薄板或帶卷為原料，并通過多架裝配了具有一定形狀的成型輥對坯料逐架次進行彎曲變形，從而得到均一最面的產品的塑性加工方法。

  一(yi)般每架成(cheng)型(xing)機裝有(you)(you)一(yi)對(dui)或多對(dui)成(cheng)型(xing)輥(gun)，每列成(cheng)型(xing)機組由兩(liang)架以(yi)上(shang)的成(cheng)型(xing)機組線(xian)。在(zai)(zai)輥(gun)式冷(leng)彎(wan)成(cheng)型(xing)過程(cheng)中只有(you)(you)彎(wan)曲(qu)變形(xing)。除坯料彎(wan)曲(qu)角(jiao)局部有(you)(you)輕微減薄(bo)外(wai)，變形(xing)材料的厚度(du)在(zai)(zai)成(cheng)型(xing)過程(cheng)中保持不變。這(zhe)種(zhong)加工方法特別適(shi)合于外(wai)形(xing)縱(zong)長(chang)、批量(liang)較大的高精度(du)產品的加工，此(ci)外(wai)，在(zai)(zai)輥(gun)式冷(leng)彎(wan)成(cheng)型(xing)過程(cheng)中，可以(yi)很容易地將沖裁、打孔、壓印、縱(zong)彎(wan)等輔助加工引入進來。

  輥式冷彎成(cheng)(cheng)型(xing)(xing)(xing)工(gong)(gong)藝(yi)(yi)可分(fen)為(wei)四種，即(ji)單張（或單件(jian)）成(cheng)(cheng)型(xing)(xing)(xing)工(gong)(gong)藝(yi)(yi)、成(cheng)(cheng)卷成(cheng)(cheng)型(xing)(xing)(xing)工(gong)(gong)藝(yi)(yi)、連(lian)續成(cheng)(cheng)型(xing)(xing)(xing)工(gong)(gong)藝(yi)(yi)和聯合加工(gong)(gong)工(gong)(gong)藝(yi)(yi)。每一種工(gong)(gong)藝(yi)(yi)都可分(fen)為(wei)3個階(jie)(jie)段(duan)(duan)，即(ji)成(cheng)(cheng)型(xing)(xing)(xing)前坯(pi)料準備階(jie)(jie)段(duan)(duan)、成(cheng)(cheng)型(xing)(xing)(xing)加工(gong)(gong)階(jie)(jie)段(duan)(duan)、型(xing)(xing)(xing)材精(jing)整階(jie)(jie)段(duan)(duan)。

  單張(zhang)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)工(gong)藝(yi)就是預定尺(chi)坯(pi)料的成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)方(fang)法(fa)。這(zhe)種(zhong)方(fang)法(fa)在坯(pi)料成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)之前將坯(pi)料切(qie)成(cheng)(cheng)(cheng)定尺(chi)長(chang)度，然后(hou)用送料輥(gun)(gun)(gun)將坯(pi)料送進成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)輥(gun)(gun)(gun)，成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)后(hou)的型(xing)(xing)(xing)(xing)材不必經剪切(qie)即可收集入庫。采用這(zhe)種(zhong)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)工(gong)藝(yi)的成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)輥(gun)(gun)(gun)的速(su)度一(yi)般在15~75m/min.這(zhe)種(zhong)工(gong)藝(yi)主要(yao)應用于(yu)小批(pi)量、成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)后(hou)型(xing)(xing)(xing)(xing)材鋸切(qie)比(bi)(bi)較困難的情況下。采用單張(zhang)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)工(gong)藝(yi)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)機組的設備(bei)較簡單、工(gong)具(ju)費用少、投(tou)資低。但用這(zhe)種(zhong)生產工(gong)藝(yi)得到的型(xing)(xing)(xing)(xing)材邊部縱(zong)向拉伸(shen)較大，因而只有(you)利用側立輥(gun)(gun)(gun)才能得到比(bi)(bi)較精確的產品(pin)形。

  成(cheng)(cheng)(cheng)(cheng)卷(juan)(juan)(juan)成(cheng)(cheng)(cheng)(cheng)型(xing)工(gong)藝(yi)和連續(xu)(xu)成(cheng)(cheng)(cheng)(cheng)型(xing)工(gong)藝(yi)基本相同，所不(bu)同的是連續(xu)(xu)成(cheng)(cheng)(cheng)(cheng)型(xing)時前一卷(juan)(juan)(juan)帶(dai)材(cai)的尾部與后一卷(juan)(juan)(juan)帶(dai)材(cai)的頭部經過(guo)齊(qi)對焊(han)，使坯料帶(dai)材(cai)連續(xu)(xu)不(bu)斷地進人成(cheng)(cheng)(cheng)(cheng)型(xing)機進行成(cheng)(cheng)(cheng)(cheng)型(xing)。而成(cheng)(cheng)(cheng)(cheng)卷(juan)(juan)(juan)成(cheng)(cheng)(cheng)(cheng)型(xing)時帶(dai)卷(juan)(juan)(juan)頭尾不(bu)對焊(han)，進行單卷(juan)(juan)(juan)供料成(cheng)(cheng)(cheng)(cheng)型(xing)。與單張成(cheng)(cheng)(cheng)(cheng)型(xing)工(gong)藝(yi)相比，這兩種成(cheng)(cheng)(cheng)(cheng)型(xing)工(gong)藝(yi)更加高(gao)效、高(gao)產(chan)、通用。這兩種成(cheng)(cheng)(cheng)(cheng)型(xing)工(gong)藝(yi)的主要優(you)點是：

①. 帶卷成本低(di)、切損(sun)少(shao)，因而降低(di)了材料總成本。

②. 由于需(xu)要(yao)(yao)的成(cheng)型(xing)機架數少(shao)且不(bu)需(xu)要(yao)(yao)額外的導衛裝置，因而工具(ju)成(cheng)本(ben)低。

③. 可以加工形狀比單張成型(xing)工藝更復雜(za)的型(xing)材(cai)。

④. 型材的(de)頭尾部扭曲及張開(kai)度減小(xiao)。

⑤. 由于操作幾乎(hu)是連續的，因而生產率得到提高。

  但這兩(liang)種成(cheng)型(xing)(xing)工(gong)藝(yi)需要(yao)開卷機(ji)、活套器、對焊機(ji)、定尺飛(fei)鋸或(huo)飛(fei)剪(jian)等輔助設備，因而其機(ji)組(zu)設備投資(zi)較(jiao)大(da)、占地較(jiao)大(da)。成(cheng)型(xing)(xing)機(ji)組(zu)的(de)成(cheng)型(xing)(xing)速(su)度一般為(wei)30~90m/min.目(mu)前投產的(de)絕(jue)大(da)多數輥式冷彎成(cheng)型(xing)(xing)機(ji)組(zu)均(jun)是采(cai)用這兩(liang)種工(gong)藝(yi)，因此后面將以這兩(liang)種成(cheng)型(xing)(xing)工(gong)藝(yi)為(wei)例進行重點闡(chan)述，圖5-1給(gei)出了其工(gong)藝(yi)流程示意(yi)圖。

  聯合加工工藝用于加工具有特定(ding)要求(qiu)的冷彎(wan)型(xing)(xing)鋼(gang)，如高強度冷彎(wan)型(xing)(xing)鋼(gang)、閉口焊接(jie)冷彎(wan)型(xing)(xing)鋼(gang)、熱處理強化冷彎(wan)型(xing)(xing)鋼(gang)、周期波紋(wen)板沖孔冷彎(wan)型(xing)(xing)鋼(gang)，涂層冷彎(wan)型(xing)(xing)鋼(gang)等(deng)。聯合加工成(cheng)型(xing)(xing)機(ji)(ji)組(zu)的設備(bei)最復(fu)雜、投資最高。根據(ju)產品的要求(qiu)這種機(ji)(ji)組(zu)可包括如下設備(bei)：直縫焊機(ji)(ji)、對焊機(ji)(ji)、輥(gun)式沖孔機(ji)(ji)、輥(gun)式壓印(yin)機(ji)(ji)、涂層機(ji)(ji)、熱處理設備(bei)等(deng)。

 輥(gun)式冷(leng)(leng)彎(wan)(wan)成型是(shi)用一組(zu)成型輥(gun)將帶(dai)材(cai)逐(zhu)漸壓(ya)彎(wan)(wan)成所(suo)需的(de)斷面(mian)型材(cai)，現(xian)以(yi)冷(leng)(leng)彎(wan)(wan)角(jiao)鋼(gang)為例，圖5-2是(shi)由4個機(ji)架(jia)(jia)組(zu)成的(de)輥(gun)式冷(leng)(leng)彎(wan)(wan)成型機(ji)組(zu)，第一機(ji)架(jia)(jia)完成帶(dai)材(cai)的(de)平整和送進工(gong)作，第二～第四(si)機(ji)架(jia)(jia)各(ge)承擔(dan)一定(ding)的(de)壓(ya)彎(wan)(wan)成型任(ren)務(wu)，使帶(dai)材(cai)通過后被彎(wan)(wan)曲(qu)壓(ya)制成角(jiao)型材(cai)。每一對成型輥(gun)所(suo)分擔(dan)的(de)彎(wan)(wan)曲(qu)變形(xing)量(liang)，決定(ding)了該機(ji)架(jia)(jia)孔(kong)型設(she)(she)計(ji)(ji)的(de)基本尺寸。不過至今的(de)孔(kong)型設(she)(she)計(ji)(ji)主要還是(shi)依靠經驗(yan)的(de)積(ji)累，尚缺乏理(li)論解析方法。