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Influence of Variable Radius Die Geometry on Tube Bending: A Finite Element Parametric Study

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Abstract:

While bending processes for producing tube bends with a constant radius have been extensively investigated in recent years, only a limited number of studies have addressed form-bound bending processes for generating variable radii. In particular, a systematic investigation of the influence of bending die geometry with a variable radius profile on tool reaction forces, geometrical and non-geometrical bent part properties is still lacking. In this study, compression bending using bending dies with a continuously varying radius is investigated by means of finite element (FE) simulations. The geometry of the bending dies is parameterized using an Archimedean spiral curve, allowing the bending radius to be described as a function of the bending angle. The introduced radial gradient, defined as the derivative of the radius with respect to the bending angle, dR/dα, serves as the central design parameter of the bending die and is systematically varied from constant radius with 0 mm/° to 1 mm/°. The influence of the radial gradient dR/dα of the bending die geometry on tool reaction forces as well as on the geometrical and non-geometrical properties of the bent part is investigated by means of a numerical parametric study for a selected bending task. The results show that for small to moderate values of dR/dα, all investigated metrics exhibit a pronounced linear dependence on the radial gradient. This behavior is further confirmed by the evaluation of the maximum values of the process and geometric parameters as a function of dR/dα, yielding high coefficients of determination (R²). For larger values of dR/dα, however, the sensitivity of both process-related and geometric characteristics decreases.

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Periodical:

Materials Science Forum (Volume 1187)

Pages:

87-98

DOI:

https://doi.org/10.4028/p-3z29kF

Citation:

Cite this paper

Online since:

April 2026

Authors:

Apostolos Aslanidis*, Jonas Reuter, Bernd Engel

Keywords:

Compression Bending, Profile Bending, Profile Forming, Radial Gradient, Tube Bending, Variable Bending Radius, Variable Radius Die

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Creative Commons CC BY 4.0

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* - Corresponding Author

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