The development of a simulation model and the determination of the die control data for the free-bending technique

A novel bending technique known as free-bending, which is particularly suitable for the bending of profile and tube cross-sections, is investigated. Advantageous characteristics, such as fast bending speed and an almost free definable bending geometry with transitionless bend-in-bends and spline bends, make free-bending highly applicable in the manufacture of car components. This paper gives an introduction to this new technique and presents the development of a finite element analysis (FEA) model for the simulation of this bending technology. Furthermore, a theoretical model for the determination of the bend die's control data is introduced. For the verification of the FEA model the simulation results are compared with the results from bending tests that have been carried out.