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. (C) 2013 The Authors. Published by Elsevier B.V.