Kaleem, Muhammad Ali
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Publication Access status: Open Access , Design and Development of Hybrid Tools for Rotary Draw Bending Using Digital Twin and Additive Manufacturing Processes(2026)Rotary draw bending (RDB) process is a profile bending process mostly used in industrial practices for bending metal tubes. Presently, RDB process is conducted by using geometry specific bending tools. The fundamental tools used in RDB process are pressure-die, bend-die, clamp-dies, wiper-die, collet and mandrel. These tools have simplified geometries with a semi-circular tool surface which corresponds to only one specific tube diameter. This makes RDB process inflexible because different tube diameters cannot be used with a specific set of bending tools. In addition to process-flexibility, the modern production regime of present era needs bending tools to be cost effective and light weight. This doctoral thesis is aimed to utilize modern manufacturing techniques, i.e., 3D printing processes and digital twin of RDB process, to develop the geometric design of bending tools which should be cost effective, light weight and provides process-flexibility to RDB process. A digital twin of the RDB process is developed and the accuracy of the digital twin is verified by comparing the FE-simulation results with practically conducted experiments. The design factors which critically influence the tool design are identified through digital twin prototyping. The digital twin prototyping method encompasses systematic development and testing of 3D printed polymeric tools in RDB process. Topology optimization of a conventional tool geometry is conducted in order to identify minimum material required within the tool. The results obtained from digital twin prototyping and topology optimization envisioned the development of a hybrid tool. A hybrid tool consists of two different materials i.e., polymers and metals. The materials of a hybrid tool are selected from Ashby material charts on the basis of requirements resulting from process parameterization and topology optimization. A model of the hybrid tool is developed according to material properties of selected materials and identified tool design factors. The model is imported in digital twin of RDB process and tool performance is investigated by conducting process simulations with different tube diameters. After obtaining process feasibility through digital twin, the hybrid tool consisting of polymer - PLA and metal - stainless steel is practically 3D printed and experimentally tested in an actual RDB process. The experimental results demonstrates that a 3D printed hybrid tool is capable of conducting bending operations with different tube diameters while enabling significant material saving within the tool. A comparison is made between the novel 3D printed hybrid tools and conventional steel tools. A design formula is presented that determines the efficiency of bending tools through Tool Efficiency index (TEi). For practical applications, the geometry of 3D printed hybrid tools is standardized through aspect ratio and corresponding upscale size factors.Source Type:Doctoral ThesisSeries:Forschungsberichte des Lehrstuhls für UmformtechnikVolume number:2028 49 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Open Access , The way forward in rotary draw bending: a reviewPresently, Rotary Draw Bending (RDB) process is one of the most common tube bending techniques used in industrial production around the world. The process is executed on a specially designed machine being fitted with specific forming tools. The quality of final products in RDB largely depends on process parameters being selected by the machine operator. These process parameters are selective balance of movements and effect of forming tools on the tubes. Substantial development has been done in identification of optimum process parameters for improving the quality of bent tubes. Each process parameter has a unique and versatile effect on quality aspects like ovality, wrinkling and fracture of the tubes. This reviewbased research is focused on gathering published information on so-far identified process parameters in RDB and their eventual effect on the tube’s quality. In the end, authors present their own perspective about the future of a RDB process. The authors perspective suggests merging of AM (Additive Manufacturing) with conventional RDB process to impart enhanced efficiency and improved quality to forming tools and bent products respectively. Apropos, a concept of hybrid pressure die is presented which encompasses manufacturing of a fundamental forming tool (pressure die) using AM techniques. The suggested model of hybrid forming tools opens a new avenue for industrialists to manufacture more flexible, cost effective and substantially beneficial tools for the RDB process in future.Source Type:InProceedings295 317 - Some of the metrics are blocked by yourconsent settings
Publication Access status: Open Access , Transformation in der BiegetechnikMit dem 6. Biegeforum hat der Lehrstuhl für Umformtechnik an der Universität Siegen ein neues Format geschaffen, in dem neben der Industrie nun auch den Forschenden ein eigener Schwerpunkt am Forum gegeben wird. Im vorliegenden Tagungsband sind Fachvorträge zum aktuellen Stand der Forschung sowie von Innovationen in der Umformtechnik zusammengefasst. Sie geben einen spannenden Einblick in hochaktuelle Forschungsergebnisse zum Biegen. Seit seiner erstmaligen Auflage im Jahr 2011 hat sich das Biegeforum zu dem etablierten Treffpunkt für Wissenschaft und Praxis entwickelt. Es findet fortan im zweijährigen Rhythmus statt.Source Type:Conference ProceedingsSeries:Forschungsberichte des Lehrstuhls für Umformtechnik696 317