Abstract
Flexible-bending is a relatively novel bending process, particularly suitable for profile and tube bending. Advantageous characteristics, such as manufacturing profiles or tubes of different radii without die change and continuous forming of bent profiles or tubes, make flexible-bending highly applicable and efficient especially in small batch production. In this paper, flexible-bending process of angle iron which is a typical asymmetric-section profile was investigated with finite element analysis method. The effect of die offset on radius of bent angle iron in outward and inward bending process was investigated. The cause and elimination method of side bending defect in bent angle irons were analyzed and compared with the experimental results. The simulation results agree well with the experimental results, which verify the feasibility of using simulation to guide the experiment. The results of both simulations and experiments indicate that the curvature of bending angle iron and side bending increases linearly with the die offset. The curvature of side bending outward is larger than the curvature of side bending inward of same die offset. The side bending defect can be eliminated by shifting the die in reverse direction of side bending.
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