Influence of the stiffness of machine axes on the formation of wrinkles during rotary draw bending

This study presents that finite element (FE) simulations of rotary draw bending are improved by taking into account the stiffnesses of the machine axes. The results show the influence of the axis stiffnesses of the bend die, the wiper die, the pressure die and the mandrel on the formation of wrinkles at the inner tube bend. For this purpose the axis stiffnesses are varied in FE-simulations and wrinkle evaluation factors of the final components are determined and compared. Low axis stiffnesses correspond to large axial displacements when force is applied and cause greater wrinkle formation. In addition, practical tests are carried out on the machine to measure the axis displacements and associated forces. The resulting axis stiffnesses are entered into the FE simulation. The final geometry of the bending component of the FE simulation is compared with the geometry of a component produced in a practical test. The consideration of the axis stiffness in the calculation in contrast to ideally stiff axes provides wrinkle heights that are closer to the wrinkle heights in the practical test. The knowledge gained improves the prediction of the component quality and allows the evaluation of axis displacements measured on bending machines. The overall aim of the project is to react to machine-specific axis stiffnesses in the form of process control.