Segmentierung von Biegeformen als Grundlage für die Entwicklung von Transformer-Werkzeugen

The transformation of manufacturing technology from mass production to individualized production or individualized mass production requires agile and flexible processes on the part of forming technology. To overcome the flexibility limitations of toolbound processes, adjustable tools are needed. To this end, this paper presents a finite element (FE) simulation-based parameter study of the segmentation of bending tools in modified compression bending. The bending dies were segmented into a fixed number, and the intersegment spacing, bending factor, and wall thickness factor are varied according to a full factorial experimental design. The effect of the segmentation is investigated based on strain contours, the histories of contact pressure, the histories of the longitudinal strains at the inner and outer arcs and based on the part geometry deviations from the geometry produced by conventional closed die surfaces. The main finding is that the (negative) effect of segmentation decreases with decreasing segment space and wall thickness factor and increases with increasing bending factor. Finally, these results were discussed in the light of the subordinate objective of the research project. The results allow us to conclude that the segmentation of bending dies, even for small bending radii, is a suitable approach to flexibilize bending processes through adjustable tools, so called transformer tools