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(mei)架成型(xing)(xing)機(ji)裝(zhuang)有(you)一(yi)對(dui)或多(duo)對(dui)成型(xing)(xing)輥，每(mei)列成型(xing)(xing)機(ji)組由兩架以上的(de)(de)成型(xing)(xing)機(ji)組線(xian)。在(zai)輥式冷彎(wan)(wan)(wan)成型(xing)(xing)過(guo)程中(zhong)(zhong)(zhong)只有(you)彎(wan)(wan)(wan)曲(qu)變(bian)形(xing)。除坯料彎(wan)(wan)(wan)曲(qu)角局部有(you)輕微減(jian)薄外(wai)，變(bian)形(xing)材(cai)料的(de)(de)厚度在(zai)成型(xing)(xing)過(guo)程中(zhong)(zhong)(zhong)保(bao)持不變(bian)。這(zhe)種加工方法(fa)特(te)別適合于外(wai)形(xing)縱長、批量較大的(de)(de)高精度產(chan)品的(de)(de)加工，此外(wai)，在(zai)輥式冷彎(wan)(wan)(wan)成型(xing)(xing)過(guo)程中(zhong)(zhong)(zhong)，可以很(hen)容易地(di)將沖裁、打孔、壓印(yin)、縱彎(wan)(wan)(wan)等輔(fu)助(zhu)加工引入進來(lai)。

  輥式冷彎(wan)成(cheng)型(xing)(xing)工(gong)(gong)(gong)藝可(ke)分(fen)為四(si)種，即單(dan)張(zhang)（或(huo)單(dan)件）成(cheng)型(xing)(xing)工(gong)(gong)(gong)藝、成(cheng)卷成(cheng)型(xing)(xing)工(gong)(gong)(gong)藝、連續成(cheng)型(xing)(xing)工(gong)(gong)(gong)藝和聯合加(jia)工(gong)(gong)(gong)工(gong)(gong)(gong)藝。每(mei)一(yi)種工(gong)(gong)(gong)藝都可(ke)分(fen)為3個階(jie)段，即成(cheng)型(xing)(xing)前坯料準備階(jie)段、成(cheng)型(xing)(xing)加(jia)工(gong)(gong)(gong)階(jie)段、型(xing)(xing)材精整(zheng)階(jie)段。

  單張成(cheng)(cheng)型(xing)(xing)工藝就是預定尺(chi)坯(pi)料(liao)(liao)的(de)成(cheng)(cheng)型(xing)(xing)方法。這(zhe)種(zhong)方法在坯(pi)料(liao)(liao)成(cheng)(cheng)型(xing)(xing)之前(qian)將(jiang)坯(pi)料(liao)(liao)切成(cheng)(cheng)定尺(chi)長度(du)，然后(hou)用(yong)(yong)(yong)送(song)料(liao)(liao)輥(gun)(gun)將(jiang)坯(pi)料(liao)(liao)送(song)進成(cheng)(cheng)型(xing)(xing)輥(gun)(gun)，成(cheng)(cheng)型(xing)(xing)后(hou)的(de)型(xing)(xing)材(cai)(cai)不必經剪切即可收集入(ru)庫。采(cai)用(yong)(yong)(yong)這(zhe)種(zhong)成(cheng)(cheng)型(xing)(xing)工藝的(de)成(cheng)(cheng)型(xing)(xing)輥(gun)(gun)的(de)速度(du)一般在15~75m/min.這(zhe)種(zhong)工藝主(zhu)要應用(yong)(yong)(yong)于(yu)小批量(liang)、成(cheng)(cheng)型(xing)(xing)后(hou)型(xing)(xing)材(cai)(cai)鋸切比(bi)較(jiao)困難的(de)情況下(xia)。采(cai)用(yong)(yong)(yong)單張成(cheng)(cheng)型(xing)(xing)工藝成(cheng)(cheng)型(xing)(xing)機(ji)組的(de)設備較(jiao)簡單、工具費用(yong)(yong)(yong)少、投資低(di)。但用(yong)(yong)(yong)這(zhe)種(zhong)生產工藝得到(dao)(dao)的(de)型(xing)(xing)材(cai)(cai)邊部縱向(xiang)拉伸較(jiao)大，因而只有利(li)用(yong)(yong)(yong)側立輥(gun)(gun)才能得到(dao)(dao)比(bi)較(jiao)精確的(de)產品形。

  成(cheng)(cheng)卷(juan)成(cheng)(cheng)型(xing)(xing)工(gong)(gong)藝和(he)連(lian)續成(cheng)(cheng)型(xing)(xing)工(gong)(gong)藝基本相同，所不同的是(shi)連(lian)續成(cheng)(cheng)型(xing)(xing)時(shi)(shi)前一卷(juan)帶(dai)(dai)(dai)材的尾(wei)部與后(hou)一卷(juan)帶(dai)(dai)(dai)材的頭部經過齊對(dui)焊(han)，使坯(pi)料帶(dai)(dai)(dai)材連(lian)續不斷(duan)地進(jin)(jin)人成(cheng)(cheng)型(xing)(xing)機進(jin)(jin)行成(cheng)(cheng)型(xing)(xing)。而(er)成(cheng)(cheng)卷(juan)成(cheng)(cheng)型(xing)(xing)時(shi)(shi)帶(dai)(dai)(dai)卷(juan)頭尾(wei)不對(dui)焊(han)，進(jin)(jin)行單卷(juan)供料成(cheng)(cheng)型(xing)(xing)。與單張成(cheng)(cheng)型(xing)(xing)工(gong)(gong)藝相比(bi)，這兩種(zhong)成(cheng)(cheng)型(xing)(xing)工(gong)(gong)藝更加(jia)高效、高產(chan)、通用。這兩種(zhong)成(cheng)(cheng)型(xing)(xing)工(gong)(gong)藝的主要優(you)點是(shi)：

①. 帶(dai)卷成本(ben)低、切損少，因而降低了材料總成本(ben)。

②. 由于需要的成型(xing)機架數少且不需要額外的導衛(wei)裝置，因而工具成本低。

③. 可以(yi)加工形狀比單張成(cheng)型(xing)工藝(yi)更復雜的型(xing)材。

④. 型(xing)材的頭(tou)尾部扭曲及張開度減小。

⑤. 由(you)于操作(zuo)幾乎是(shi)連續(xu)的(de)，因而生產率得到提高。

  但這兩(liang)種成(cheng)型(xing)工(gong)(gong)藝需要開卷(juan)機(ji)(ji)(ji)、活套器(qi)、對(dui)焊(han)機(ji)(ji)(ji)、定(ding)尺(chi)飛(fei)鋸或飛(fei)剪(jian)等(deng)輔(fu)助設備(bei)，因而其機(ji)(ji)(ji)組設備(bei)投資較大(da)、占地較大(da)。成(cheng)型(xing)機(ji)(ji)(ji)組的(de)成(cheng)型(xing)速度(du)一般(ban)為30~90m/min.目前投產(chan)的(de)絕(jue)大(da)多數輥式(shi)冷(leng)彎成(cheng)型(xing)機(ji)(ji)(ji)組均(jun)是采用這兩(liang)種工(gong)(gong)藝，因此后面將以這兩(liang)種成(cheng)型(xing)工(gong)(gong)藝為例進行重(zhong)點闡述，圖(tu)5-1給出了其工(gong)(gong)藝流程示(shi)意(yi)圖(tu)。

  聯合加工(gong)(gong)工(gong)(gong)藝用(yong)于(yu)加工(gong)(gong)具有特定(ding)要(yao)求的冷(leng)(leng)彎型鋼，如高強度冷(leng)(leng)彎型鋼、閉口焊(han)接冷(leng)(leng)彎型鋼、熱處(chu)理強化冷(leng)(leng)彎型鋼、周期波紋板沖孔冷(leng)(leng)彎型鋼，涂(tu)層(ceng)冷(leng)(leng)彎型鋼等(deng)(deng)。聯合加工(gong)(gong)成型機(ji)組的設(she)備(bei)最(zui)復雜、投資最(zui)高。根據產品的要(yao)求這種機(ji)組可包括如下設(she)備(bei)：直縫焊(han)機(ji)、對焊(han)機(ji)、輥式沖孔機(ji)、輥式壓印機(ji)、涂(tu)層(ceng)機(ji)、熱處(chu)理設(she)備(bei)等(deng)(deng)。

 輥式冷(leng)(leng)彎成型(xing)是用一組(zu)成型(xing)輥將帶(dai)材逐漸(jian)壓(ya)彎成所(suo)需(xu)的(de)(de)斷面(mian)型(xing)材，現以冷(leng)(leng)彎角鋼為例，圖5-2是由4個機架組(zu)成的(de)(de)輥式冷(leng)(leng)彎成型(xing)機組(zu)，第(di)一機架完成帶(dai)材的(de)(de)平整和送進(jin)工作，第(di)二～第(di)四機架各(ge)承擔(dan)一定(ding)的(de)(de)壓(ya)彎成型(xing)任務，使帶(dai)材通過后被彎曲壓(ya)制成角型(xing)材。每一對成型(xing)輥所(suo)分擔(dan)的(de)(de)彎曲變形量，決定(ding)了該機架孔型(xing)設計的(de)(de)基本尺(chi)寸。不過至今的(de)(de)孔型(xing)設計主要還是依靠經驗的(de)(de)積(ji)累，尚缺(que)乏理論解析(xi)方法。