Design of process parameters for the incremental tube forming (ITF) by FEM to control product properties

摘要

The incremental tube forming (ITF) is a process combination of the kinematic tube bending and spinning to shape high strength and tailored tubes with variable diameters and thicknesses. In contrast to conventional bending methods, the compressive stress superposition by the spinning process facilitates low bending stresses, so that geometrical errors are avoided and the shape accuracy is improved. The study reveals the interaction of plastic strains of the rolling and bending process through an explicit FEM investigation. For this purpose, the three-dimensional machine set-up is discretized and modeled in terms of the fully disclosed spinning process during the gradual deflection of the tube end for bending. The analysis shows that, depending on the forming tool shape, the stress superposition is accompanied by high plastic strains. Furthermore, this phenomenon is explained by the three dimensional normal and shear strains during the incremental spinning. Analyzing the strains history also shows a nonlinearity between the strains by bending and spinning. It is also shown that process parameters like rotational velocity of the spinning rolls have a huge influence on the deformation pattern. Finally, the method is used for the manufacturing of an example product, which reveals the high process flexibility. In one clamp a component with a graded wall thickness and outside diameter along the longitudinal axis is produced.