FEA Simulation of Free-Bending - A Preforming Step in the Hydroforming Process Chain

N. Beulich, P. Craighero, W. Volk

Research output: Contribution to journalConference articlepeer-review

27 Scopus citations


High-strength steel and aluminum alloys are essential for developing innovative, lightly-weighted space frame concepts. The intended design is built from car body parts with high geometrical complexity and reduced material-thickness. Over the past few years, many complex car body parts have been produced using hydroforming. To increase the accuracy of hydroforming in relation to prospective car concepts, the virtual manufacturing of forming becomes more important. As a part of process digitalization, it is necessary to develop a simulation model for the hydroforming process chain. The preforming of longitudinal welded tubes is therefore implemented by the use of three-dimensional free-bending. This technique is able to reproduce complex deflection curves in combination with innovative low-thickness material design for hydroforming processes. As a first step to the complete process simulation, the content of this paper deals with the development of a finite element simulation model for the free-bending process with 6 degrees of freedom. A mandrel built from spherical segments connected by a steel rope is located inside of the tube to prevent geometrical instability. Critical parameters for the result of the bending process are therefore evaluated and optimized. The simulation model is verified by surface measurements of a two-dimensional bending test.

Original languageEnglish
Article number012063
JournalJournal of Physics: Conference Series
Issue number1
StatePublished - 27 Sep 2017
Event36th IDDRG Conference 2017: Materials Modelling and Testing for Sheet Metal Forming - Munich, Germany
Duration: 2 Jul 20176 Jul 2017


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