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Flexible flow splitting enables manufacturing a new kind of semi‐finished goods: bifurcated sheet metal in integral style with non‐linear progression of the bifurcation line. Beside special geometrical features, this forming process is associated with severe plastic deformation (spd) processes. Due to the strategy of process guidance, it is possible to process diverse parts with different geometry and mechanical behavior without changing of tools or programming. To predict complex flow splitting processes with the help of FEM simulation, methods like the cut and expand method (CEM) have been developed in the recent past, to decrease calculation time and increase efficiency of the simulation. As the flexible flow splitting process is a non‐steady forming process, this method is no longer suitable and has to be adapted. A further development of the cut and flexible expand method (CfEM) will solve this problem. This paper will present the operation mode of the process and the simulation method. The characteristics of this forming process and a comparison of experimental and numerical results will be presented.

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Linear flow splitting is a multi-station sheet-bulk metal forming process which allows continuous production of bifurcated profiles without joining, lamination or external heating of sheet metal. This process induces high hydrostatic stresses in the forming zone which leads to an elevated formability of the workpiece material. The aim of this research is to bend linear flow split profiles in transverse direction in a continuous manner. This is achieved by combining the linear flow splitting process with a continuous bending process. An analytical and a numerical model are described in this paper which predict bending moments for different radii. Results from both models are validated with experimental results. It is found that combining the linear flow splitting with a bending process leads to a severe reduction in the bending moments due to superposition of stresses in the forming zone. The superposition maintains the cross sectional shape of the bent profiles.