Flexible roll bending process and improved forming characteristics of integral panel with an elastomer-covered roller system

The manufacturing of next-generation aerospace components demands integral aluminum alloy panel that combine large dimensions, light weight, and high precision. Conventional rigid roll bending, however, often results in surface concavity and rib buckling during the forming of such thin-walled structures. Here, a flexible roll bending process using an elastomer-covered roller system is proposed to mitigate these issues. A finite element model of the forming process for high-strength aluminum alloy integral panel is established and experimentally validated. The influence of elastic layer hardness and press amount on stress distribution, curvature radius, and generatrix linearity are systematically investigated. The results reveal that, compared to rigid roll bending, the flexible approach achieves a markedly more uniform stress distribution across stiffened ribs, with a 34.3% reduction in peak stress. At an optimal press amount of 17.5 mm and an elastic layer hardness of 95A, generatrix straightness coefficient is improved by 51.6%. This work establishes a robust framework for advancing roll forming techniques in the fabrication of high-performance integral aerospace structures, offering both a viable manufacturing strategy and theoretical support.