Abstract: In order to realize the freeform surface parts formed with the efficiency and economy, the ordinary methods of flexible forming are analyzed. Based on forming process continuity, flexible forming can be classified sectional forming and continuous forming, and according to deformed area it can be divided into point, facet and line forming. Through comparing different forming methods, a critical problem to achieve high quality and high efficiency forming the freeform surface parts is proposed. Based on the above analysis, a novel idea of forming freeform surface parts by the continuous line forming that has characteristic of efficiency and flexibility is proposed. And the technology project of forming the freeform surface parts by adopting the multipoint continuous forming technology using multipoint adjustable rollers is developed. Moreover, basic principle, key technologies and characteristics of multipoint continuous forming are discussed. Subsequently, the novel flexible roller forming means which has a flexible shaft with many controllable points is applied and the experimental device concerned with this technology using the multipoint adjustable rollers is developed. The results of the continuous forming experiments on forming kinds of 3D surface parts makes it clear that the above technology is suitable to solve the critical problem of the freeform surface parts forming with high effi-ciency.

Key words: Bending, Continuous forming, Flexible forming, Freeform surface, Multipoint forming, Plastic forming, Roll forming