Controlling the fields of tolerance by linear flow splitting


Linear flow splitting enables the forming of bifurcated profiles in integral style. The producability of linear flow splitting profiles has been proven within the Collaborative Research Centre 666 at the TU-Darmstadt. Studies revealed that bifurcated profiles in integral style with defined lengths of flanges are possible. Further knowledge about the achievable tolerances under industrial conditions for the commercial usage is requred.


Aim of the transfer project is the analysis of the required precision of parts produced by linear flow splitting for commercial usage and the deduction of techniques for achieving these fields of tolerance in a linear flow splitting process. The producible tolerances are to be documented by using two products (Figure 1). In order to realize the allowed tolerances actions have to be deducted and put thru to achieve the required fields of tolerance. Therefore a further processing of the web and the flanges of the bifurcated profiles is necessary. Due to many adjustment possibilities of the linear flow splitting tools a simplification of the setup and a research of the influence of disturbances, e.g. the false position of a roll forming tool, are further aims of the transfer project.


In a first step an analysis of the product specifications is made and the desired geometry is defined. Following is the layout and design of the process chain to produce the defined parts. In a subsequent step the layout and construction of the tools for the single process is made. Parallel a numerical sensitivity analysis of the process steps is put thru. Following the achievable fields of tolerance are to be investigated experimentally. Techniques to control the found fields of tolerance are being put up. The techniques will then be used to develop suitable setting up strategies to control the fields of tolerance of a linear flow splitting process.

This transfer project is carried out within the Collaborative Research Centre (CRC) 666 “Integral sheet metal design with higher order bifurcations” by the Deutsche Forschungsgemeinschaft. Further on we would like to thank our cooperative partners for the support.

Cooperative partners