Kinematic Tool-Based Profile Bending Using Transformer Tools II
This research project (509709804), funded by the German Research Foundation (DFG), investigates methods for resolving and adjusting the active surfaces of bending dies, as well as modeling methods for the algorithmic design of movable lightweight truss structures. The overarching goal is to make form-constrained bending processes more flexible by transitioning them toward partially kinematic processes.
Project Description
Tool-based profile bending processes are limited by the fixed tool geometry in terms of the component geometries that can be produced. The project therefore investigates flexible bending dies whose active surfaces can be adjusted during the forming process using actively adjustable segments. This is intended to enable partially kinematic shaping and reduce the required tooling effort.
To this end, the relationships between segment kinematics, forming mechanisms, and component properties are being investigated. At the same time, load-bearing truss structures are being developed that enable the necessary movements of the die segments and absorb the forming forces. The forming requirements are coupled with methods for the algorithmic design of the truss structures. The developed approaches are implemented using additively manufactured demonstrators of transformer dies and are experimentally investigated.
Project Focus Areas:
- Flexible die working surfaces: In-process adjustment of segmented bending dies
- Forming technology: Investigation of segment kinematics, forming mechanisms, and component properties
- Truss structures: Algorithmic design of movable, load-bearing lightweight structures
- Transformer dies: Integration of forming technology and structural design, as well as the implementation of additively manufactured demonstrators
Everything at a Glance
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Duration
January 1, 2023 – February 28, 2027 (Ongoing) -
Research Area
Production Engineering -
Funding
German Research Foundation (DFG): €568,000
Research Methods & Procedures
Analysis of Forming Mechanisms
This study examines the effects of segmented die working surfaces on the bending of closed profiles. In particular, it focuses on the relationships between die segmentation, forming mechanisms, and the resulting component properties.
Analysis of Segment Kinematics
The tool segments are examined as actively adjustable elements. The study analyzes how different segment movements alter the tool’s active surface during the forming process and influence the part geometry.
Algorithmic Structural Design
The load-bearing tool structure is designed using mixed-integer programming. In this process, suitable truss structures are identified, taking into account their load-bearing capacity and kinematic properties.
Coupling of Forming and Structure
The forming requirements for the die segments are integrated with the algorithmic structural design. The methods developed are then implemented in additively manufactured transformer dies and evaluated experimentally.
