System for optimisation of product and process design in profile bending

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System for optimisation of product and process design in profile bending

Chatti, S. / Klimmek, C. / Kleiner, M.

The demand für aluminium and steel profiles as important structural components increased during the last years. These profiles are used in automobile production in linear and bent contours. A high bending quality is an important condition for subsequent production steps like assembly and welding and can therefore reduce the costs of the entire production chain. At the Chair of Forming Technology (University of Dortmund) a concept for a system to optimise product and process design in profile bending has been developed. The aim is to increase the accuracy of the shape and the desired curvature as well as the process flexibility. Within the system a semi-analytical process simulation is used for the generation of NC-data. Finite element simulations are used to analyse cross-section deformations prior to the real bending process. The results of the finite element simulations will enable a bending specific design of the cross-section shape of the profiles. Disturbances like material variations from lot to lot which cannot be dealt within the simulations will be compensated with an online control process system.