Motion profile calculation for freeform bending with moveable die based on tool parameters

Werner, Matthias Konrad; Maier, Daniel; Scandola, Lorenzo; Volk, Wolfram

doi:10.25518/esaform21.1879

Cited by 9 publications

(6 citation statements)

References 3 publications

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“…Another simulation model for freeform bending as the preform forming step of hydroforming was also investigated [7]. A simulation model is used to calculate the motion profile of the bending die to get better geometrical accuracy results while reducing scrap [8]. If only a 2D bending part is manufactured, the hole part can be described by the parameters radius and bending angle.…”

Section: State Of the Artmentioning

confidence: 99%

Experimental analysis on the influence of freeform bending on Barkhausen noise for steel tubes

Maier

2023

Materials Research Proceedings

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Abstract. Freeform bending with a movable die makes it possible to bend complex structures and seamless radii without changing the bending tools. Currently, most research focuses on minimizing the geometrical deviations without considering the mechanical properties of the bent tubes. A previous work showed, that the geometry can be decoupled from the mechanical properties with non-tangential bending [1]. The implementation of a soft sensor based on ultrasonic contact impedance measurements (UCI) of the property-controlled freeform bending has also been examined [2], as well as a structure for closed-loop control based on material properties [3]. The present work deals with a micro-magnetic sensor and Barkhausen noise (BHN) and investigates its suitability for the closed-loop control. For this purpose, different processing routes for freeform-bent steel tubes are experimentally investigated by their characteristic BHN. In addition to an existing simulation model, a data basis for the impact of freeform bending parameters is built to extend the existing model of a property-based closed-loop control.

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Section: State Of the Artmentioning

confidence: 99%

Experimental analysis on the influence of freeform bending on Barkhausen noise for steel tubes

Maier

2023

Materials Research Proceedings

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“…Due to the technology's many remarkable advantages, it has been widely used in aerospace, nuclear power, automobiles, ships, and many other engineering fields [27]. On the other hand, compared to rotary draw bending, which relies on mold constraints [28], the FBF process offers less constraint on the tube during bending. This leads to increased complexity in affecting factors.…”

Section: Introductionmentioning

confidence: 99%

“…Currently, the FBF forming process equipment mainly includes three-axis, five-axis, six-axis, and even seven-axis components based on a parallel mechanism [27][28][29]. This technology encompasses a three-axis free-bending mechanism, which consists of five main parts: the bending die, spherical bearing, guiding, compacting, and propulsive mechanisms [27].…”

Section: Introductionmentioning

confidence: 99%

“…This technology encompasses a three-axis free-bending mechanism, which consists of five main parts: the bending die, spherical bearing, guiding, compacting, and propulsive mechanisms [27]. All FBF experiments focus on accurately controlling the bending die's trajectory in the bending process [28]. The distance between the center of the bending die and the center axis of the propulsion section of the tube is called eccentricity U [29].…”

Section: Introductionmentioning

confidence: 99%

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Modeling and Experimental Investigation of U-R Relationship of AA6061-T6 Tubes Manufactured via Free Bending Forming Process

Abd El-Aty,

Cheng,

et al. 2023

Materials

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Forming tubes with various bending radii without changing the bending dies is much easier for the 3D free bending forming (FBF) process. In the 3D-FBF process, different bending radii were realized by adapting the eccentricities of the bending dies. The accuracy of the U-R curve is crucial for the precision forming of complex bending components. In this study, the U-R relation curve of the Al alloy tube with a specific friction coefficient, fixed geometry size, clearance between tubes, and bending die was fitted first based on the forming results of AA6061-T6 tubes under different eccentricities. Second, the U-R relationship curve based on the experiment is used to propose the U-R relationship’s mathematical formula based on many hypotheses. Finally, the modified U-R mathematical formula was applied in the finite element (FE) simulation and the actual FBF experiments for the AA6061-T6 Al alloy complex shape space bending members. The U-R relationship curve’s reliability was verified by comparing the simulation and experimental results. The results obtained from the modified U-R relationship align well with the FE modeling results and can be directly applied to the bending process for the intended components.

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“…Although smaller radii can still be achieved with rotary-draw-bending [2], the flexibility of freeform bending allows to reduce the tooling costs and the manufacturing time for complex parts. Similarly to three-roll push bending [3], the process is kinematics-based and the deformation of the part is realised through the relative motion of the bending head with respect to the fixed holder [4]. Different machine configurations have been proposed for realising the freeform bending principle.…”

Section: Introductionmentioning

confidence: 99%

Impact of the process velocities on the quality of free-form bent parts

Scandola,

Tschannerl,

Maier

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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The geometrical accuracy of the bent components as well as their surface quality are crucial parameters to evaluate the feasibility of a bent geometry in free-form bending. In the process the deformation of the part is obtained by displacing and rotating a movable bending head with respect to the fixed holder with a given relative velocity with respect to the feed velocity. High process velocities have a beneficial effect on the realisation of bending radii and angles, but induce high local solicitations on the semi-finished part, which can result in surface defects like indentations and buckles. In this work the impact of the bending head velocity as well as of the feed velocity on the bend’s stability and the arising of indentations is investigated. Experimental tests with different head and feed velocity are conducted on mild, moderate and severe bends keeping the same kinematics. The resulting bending radii, angles and surface defects are evaluated. The results allow to identify the parameters having the highest influence on the quality of bent profiles and to propose a compromise between geometrical stability and surface quality.

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Motion profile calculation for freeform bending with moveable die based on tool parameters

Cited by 9 publications

References 3 publications

Experimental analysis on the influence of freeform bending on Barkhausen noise for steel tubes

Experimental analysis on the influence of freeform bending on Barkhausen noise for steel tubes

Modeling and Experimental Investigation of U-R Relationship of AA6061-T6 Tubes Manufactured via Free Bending Forming Process

Impact of the process velocities on the quality of free-form bent parts

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