Validation of numerical simulations for the reduced freeform bending process using a test bench

"Freeform bending provides a wide range of possibilities to design com-plex bending parts based on tubes as well as on profiles. Currently, common in-efficient trial-and-error procedures are used for designing and manufacturing freeform bending parts. Numerous iterations, consisting of subsequent real tests, are needed to achieve accurate parts within the tolerances and with the intended quality. The compensation of deviations during the trial-and-error procedure mostly depends on the operator’s experience instead of defined and transferable methods. In this work a basic simulation model for freeform bended profiles with rectan-gular cross-section is introduced. Within this simulation model the complexity of the freeform bending process is reduced to investigate on essential process pa-rameters. Furthermore, different shell element types are examined as well as hardening effects during the preforming process of the profiles. Further on, a test bench is used to validate the simulation model with real experimental data. This work establishes the basis for further investigations in order to understand and improve the freeform bending process of rectangular shaped steel tubes."     «

"Freeform bending provides a wide range of possibilities to design com-plex bending parts based on tubes as well as on profiles. Currently, common in-efficient trial-and-error procedures are used for designing and manufacturing freeform bending parts. Numerous iterations, consisting of subsequent real tests, are needed to achieve accurate parts within the tolerances and with the intended quality. The compensation of deviations during the trial-and-error procedure mostly depends on the operator’s...     »