Extending the Process Limits of Conventional Rotational Bending by Implementing an Incremental Bending Feature (iRDB)
As part of the Central Innovation Program for Small and Medium-Sized Enterprises (ZIM), the project is being carried out in collaboration with Transfluid Maschinenbau GmbH. The goal is to develop an incremental bending feature for rotational draw bending (iRDB) in order to expand its process limits and enable the cost-effective production of large bending radii.
Project Description
The increasing complexity of thin-walled bent components in terms of required features (large and small bending radii, S-bends, short radius transitions, changes in bending planes) calls for continuous integration and further development of manufacturing processes. With rotational draw bending, these features can theoretically be produced using just one machine. However, the process is not economical for large bending radii due to the required machine footprint and high tooling costs. The goal of the project is to research and develop an incremental bending feature in rotational draw bending (iRDB) to expand the process limits.
Everything at a Glance
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Duration
March 1, 2026 – February 28, 2028 (Ongoing) -
Research Area
Production Engineering -
Funding
Federal Ministry for Economic Affairs and Energy (BMWE) as part of the Central Innovation Program for SMEs (ZIM)
Research Methods & Procedures
Definition
The first step is to define the technical requirements for the machine design and the required kinematics.
Process Simulation
A numerical process simulation is performed to determine the load distribution on the machine, along with a sensitivity analysis of process variables relevant to metal forming. Recommendations for selecting an appropriate increment size are developed.
Benchmark Components & Digital Twin
After the prototype machine has been developed and commissioned, benchmark components are manufactured using incremental bending and compared with the digital twin from the process simulation.
