Development of a simulation model for the automatic optimization of tools for multi‐dimensional tube forming

Abstract

AbstractThe increasing number of vehicle components and the advancing lightweight construction in manufacturing processes increasingly require a more flexible design of the exhaust tube geometry. The use of process supplementary simulations is necessary, in order to meet these increasing requirements in the future.The aim of this study is the development of a software tool for the simulation of multi‐dimensional tube forming processes by tube bending and tube embossing. Therefore, a graphical user interface was developed to build‐up and simulate the tube forming processes. The required material parameters for the numerical modeling were determined by means of tensile tests. The simulation models were successfully validated by comparing the numerical results with the experimental results. The influence of the workpiece and the forming tools were numerically investigated on the basis of the validated simulation models. Batch‐related tolerances could be identified as a serious source of deviations. Furthermore, experimental forming errors could be numerically reproduced and corrected by modifying the parameter settings. The tool variation increased the process knowledge and provided the basis for a subsequent optimization. The embossing structure could be optimized satisfactorily by specifying user‐defined requirements.