Abstract
The improvement of the stiffness properties of the lightweight constructions using structured sheet metals is becoming more and more popular. These sheet metals have a three-dimensional geometry which causes better stiffness, heat conductivity and acoustic properties. However, this geometry brings besides many advantages several challenges for the following processing of these sheet metals. The main challenge is the different material behaviour depending on the bending position and structure location. In this work, the air bending of structured sheet metals was investigated. A numerical model was developed to predict the process safety and the bending line form. The model consists of two separate steps: hydroforming (manufacturing process of structured sheet metals) and air bending. Each simulation step was validated by series of experiments. The results show that the structured sheet metal has favourable and not favourable bending positions. At the structure location “positive” the bending quality is better than at the “negative”. Furthermore, the FE model allows the prediction of the strains in the bending zone in variable bending position and analysis of the process parameters of both forming steps.
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