Process Model for the Design of Bent 3-dimensional Free-form Geometries for the Three-roll-push-bending Process

Three-Roll-Push-Bending is a highly flexible manufacturing process for the production of 3-dimensional free-form bent tubes. In the scope of this paper the process behavior for the manufacturing of 3-dimensional geometries is investigated. A FE model which considers all of the relevant influences, such as the machine's kinematic, the friction and the machine stiffness has been developed. A variant simulation investigating the impact of the process parameters on the shape of the resulting helical structures has been carried out. This allows a methodical process design for the manufacturing of 3-dimensional free-form geometries.