提出一种将解析数学模型和有限元模型结合起来的方法来研究三辊滚弯成形过程。两模型分别定量求解及模拟分析了内辊下压加载位移量与板料弯曲回弹半径之间的非线性关系。并将此应用于一半圆形板材工件(3105 mm×714 mm×545 mm)的成形模拟及实验加工中。结果表明,该解析数学模型和有限元数值模型都能较精确预测内辊位移加载量,有限元模型比基于三点梁弯曲理论的数学模型更接近实际的成形过程,利用数值模拟优化后的参数进行实际成形的工件的平均误差为+0.715/-0.652 mm,完全满足形位精度要求,说明该解析模型及数值模拟方法合理有效。 A method of combining the analytical mathematic model with the finite element model is proposed to study the three-roll roll forming process. The two models are used to quantitatively solve and simulate the nonlinear relationship between the displacement of inner roller and the bending radius of rebound. This was applied to the forming simulation and experimental machining of a half-circular plate workpiece (3105 mm × 714 mm × 545 mm). The results show that both the analytical model and the finite element numerical model can accurately predict the displacement of the inner roller. The finite element model is closer to the actual forming process than the mathematical model based on the three-point beam bending theory. By using the numerical simulation of the optimized parameters The average error of the actual workpiece is +0.715 / -0.652 mm, which fully satisfies the requirement of shape accuracy, which shows that the analytical model and the numerical simulation method are reasonable and effective.