Verfahrensentwicklung 3D-Schwenkbiegen

With increasing individualization, mass production is evolving towards personalized manufacturing, which is characterized by smaller batch sizes and a greater variety of variants. This increases the need for flexible manufacturing technologies. 3D-swivel-bending is an innovative approach to the low-tool production of complex profile components, particularly due to its ability to realize non-linear and three-dimensional bending edges and free-form surfaces. The development of this process aims to create more efficient and flexible methods for the manufacturing of components with variable cross-sections and load-adapted components. An important aspect is the extension of the swivel-bending principle by additional degrees of freedom to enable the shaping of non-linear bending edges and free-form surfaces. The process is based on a modified process instruction in which the axis of rotation of the bending tool is shifted relative to the bending edge, and adapted tool geometries are developed. The forming mechanisms and effects of 3D-swivel-bending are analyzed in a process design in order to describe the properties of the manufactured parts and the process limits analytically. Various methods for characterizing the mechanical behavior are presented in the process modelling to derive a process window for 3D-swivel-bending. This enables precise characterization of the forming mechanisms. The process window shows the working field of 3D-swivel-bending and can be used to evaluate and design future geometries. A validation of the developed methods evaluates the applicability of 3D-swivel-bending in industrial contexts and demonstrates technological and economic advantages. It shows that 3D-swivel-bending is particularly suitable for small and medium batch sizes in the automotive and aerospace industries, as well as in the construction sector. The process extension focusses on improvements in flexibility and applicability. Hybrid bending kinematics and new technologies for tool production and bending sequence planning are being developed. In addition, a process generator for digital planning and optimization of the production process is introduced.
Thanks to its flexibility and efficiency, 3D-swivel-bending offers an innovative solution for complex components. It is particularly suitable for small batch sizes in industrial sectors and combines technological and economic advantages.