Numerische Simulation einer neuartigen Prozesskette zur Herstellung von Rohren mit veränderlichem Querschnitt – Numerical simulation of a novel process chain for the manufacturing of closed tubes with variable cross-sections

Numerical simulation of a novel process chain for the manufacturing of closed tubes with variable cross-sections

Masterthesis, Bachelorthesis

Many products today are assembled from a large number of subcomponents because it is not possible to manufacture them from one part. An example of this is the car axle housing, which has to be assembled in many steps due to the large cross-sectional changes.

With the worldwide novel production process “Flexible Roll Beading” developed at PtU, large diameter transitions in pipes can now also be realized. In the first step, beads are introduced into the sheet metal for this purpose. These beads store additional material, which in the last step is used by internal high pressure forming (IHU) to produce larger diameters.

The work presented includes the following tasks:

  • - Numerical modeling of the entire process chain:
  • (1. flexible roll beading -> 2. bending or roll forming to a closed tube -> 3. widening of the tube by IHU)
  • - Investigation of the influence of beads on the IHU process