Reuter, Jonas
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Publication Access status: Open Access , Methode zur Gestaltung segmentierter Werkzeuge für die Flexibilisierung von Biegeprozessen(2026)The megatrends of neo-ecology, connectivity, and individualization are fundamentally transforming manufacturing technology. From the perspective of sheet and profile forming processes, these megatrends generate the need for resource-efficient and highly flexible production methods. Common industrial bending processes with geometric-specific tools, such as rotary draw bending or compression bending, have limited flexibility because the final contour of the bent part is predetermined by the tool shape. Approaches to enhance flexibility include the segmentation of closed tool surfaces, allowing for adjustable tool contours. Previous investigations in this area have been limited to large sheet metal components or profile bending parts with large bending radii in the context of multi-point forming. This work presents a systematic methodology for designing segmented bending tools, using compression bending as the example process. This methodology focuses on investigating the cause-effect relationships between surface topology of the forming tools, the mechanical and geometric properties of the semi-finished product, and the resulting forming phenomena and mechanisms. Segmented tools affect nearly all geometric characteristics of the bent components. This is primarily due to a combination of cross-sectional ovalizations and free bending over the segment gaps, which superimpose base bending. Despite these unavoidable limiting forming mechanisms, high-quality parts can be produced through an appropriate process and tool setup. The developed design methodology provides a solid knowledge base and characteristic diagrams for determining gap dimensions, segment geometries, and process parameters. Furthermore, in-process adjustments to the segments demonstrate the tools' expanded range of applications. This enables for the targeted suppression of limiting forming mechanisms that are typically active in statically segmented tools. Looking ahead, such adaptive tools will require load-bearing structures that can withstand process forces and facilitate necessary segment movements. As a first step towards this aspect, the investigations conducted in this research work introduce a novel approach of topology optimization of forming tool structures based on the mathematical optimization of truss-like structures using mixed-integer programming.Source Type:Doctoral ThesisSeries:Forschungsberichte des Lehrstuhls für UmformtechnikVolume number:1940 1552