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.

Sheet metal is available in a wide range of properties and material composition. There are standardized quality characteristics for mechanical and geometrical properties in the plane of the sheet. However, the band edges are influenced by the correspondent metal working process and the properties may vary or be unknown. The forming zone of the manufacturing process linear flow splitting is located at the band edge. Thus, the knowledge of probable influences of metal working induced band edge properties on the process of linear flow splitting is essential and this knowledge will be presented in the following article.Keywords: Linear flow splitting / band processing / quality of semi-finished goods / influencing parameters / sensitivity analysis Das Halbzeug Blech ist in einem breitem Werkstoff-und Eigenschaftsportfolio verfügbar. Von den Herstellern werden für das mechanische Verhalten und die geometrischen Eigenschaften zahlreiche Qualitätsmerkmale sichergestellt. Für den Bereich der Bandkante gibt es jedoch keine standardisierten Kriterien. Diese wird durch das entsprechende Bearbeitungsverfahren beeinflusst. Bei dem Massivumformverfahren Spaltprofilieren liegt die Umformzone genau an der Bandkante. Die Kenntnis über den Einfluss der Kantenbearbeitung auf den Spaltprofilierprozess ist daher essentiell und soll in diesem Beitrag aufgezeigt werden.

No abstract

There is a significant demand on flexibility in production processes, regarding freedom of part design and freedom of process design. The forming process linear flow splitting satisfies these demands by enriching the semi‐finished product sheet metal with geometric features. Additional flanges and bifurcations in integral style expand the range of component applications. By the further development of flexible flow splitting, these flanges can now be produced along a non‐linear bifurcation line and the application can be expanded on products with varying cross‐section. The continuous steady‐state process linear flow splitting is transferred into a flexible forming process that is characterized by non‐steady states and measurands. Methods of materials characterization are applied to investigate, if those non‐steady properties, that are visible in process characteristics and part geometry, can also be identified in the mechanical behavior.