The bending technique Free Bending is used in the hydroforming process chain as a preforming step for tube profiles at the automotive manufacturer BMW. In this master’s thesis a finite element model for the Free Bending machine in LS-Dyna has to be developed and validated. The characterization of input values for a free bending simulation model requires an initial analysis of the manufacturing process of the metal pipe. This forming process is also developed as a FE model. After the optimization of the process parameters, the model is validated by material tests. As a result of this simulation, the pre-damage of the material can be interpreted from material dependent charts to get a summary of the material properties. Additionally, the resultant values are mapped to plain tubes to create a realistic pre-product for any subsequent forming simulation. Starting from the results of the tube manufacturing simulation, the Free Bending simulation is developed with respect to the machine kinematics and the bending mandrel. The validation of the free bending simulation model is realized with processing and optical measurements of two different bending profiles. By the comparison of the simulations and the bending tests, an accurate reproduction is measured Possibilities for the optimization and the improvement of the free bending simulation model are shown in the outlook. Also opportunities for the integration and application of the model in automated processes are pointed out.
|Translated title of the contribution||Simulation of the Free Bending of tube profiles for the automotive industry|
|Award date||21 Oct 2016|
|Publication status||Published - 2016|
Bibliographical noteembargoed until 04-07-2021