Abstract: Three roller bending machines are widely used for shaping metallic components critical in industries such as automotive and aerospace. This review analyzes the effects of roller diameter and number of passes on power consumption in these machines. Larger roller diameters enhance contact mechanics by increasing the contact area, which reduces bending forces, torque requirements, and consequently power consumption. Additionally, multi-pass bending distributes deformation incrementally, lowering peak power demands per pass but increasing total operation time and energy use. The interaction of these parameters influences energy efficiency, dimensional accuracy, surface finish, and springback behavior. Theoretical models rooted in bending moments and torque-speed relationships corroborate empirical findings. Advancements in Industry 4.0 and AI-driven process control offer promising avenues for real-time optimization of these parameters, potentially enabling significant energy savings and quality improvements. Despite progress, research gaps persist in adaptive control systems for power optimization. This article synthesizes current knowledge, discusses practical implications for machine design and process management, and suggests future research directions focused on intelligent, data-driven bending operations.

Keywords: Three roller bending machines, Power consumption, Roller diameter, Number of passes, Energy efficiency

Downloads: | DOI: 10.17148/IARJSET.2025.121020