Using set-based design for developing a 3D metal forming process

Abstract

Industry is continuously searching for solutions to increase flexibility and quality in parallel with cost reductions. This paper presents a case study of using set-based design method to develop a gripping system for an innovative three-dimensional bending and forming technology of extruded aluminium profiles. Traditionally, profiles are formed by mandrel-based stretch-bending to improve cross-sectional stability and spring-back, sometimes combined with subsequent calibration e.g. by hydroforming. However, in the highly competitive automotive industry, where light-weighting is high on the agenda, design and process flexibility, tooling cost and dimensional accuracy are important factors to increase value at a reasonable cost. In this paper, a set-based concurrent engineering approach is used to identify, evaluate and prioritize gripping methods to enable three-dimensional bending meeting automotive requirements for dimensional accuracy. The results demonstrate a multitude of options, providing trade-offs between flexibility and function. Further work will be to build a physical demonstrator to validate output from the set-based method used to systematically narrow down the solution space.