Property-controlled process design of freeform bending considering material properties of the semi-finished product

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The overall objective of the overall research project is the scientific elaboration of a soft sensor-based control structure that reacts to fluctuations in the semi-finished product as well as in the process. As required for a given target geometry, the control structure is able to adjust residual stresses and other mechanical properties (hardness, ductility, strength) in the bent tube. Based on this formulation of objectives, sub-objectives building on one another were formulated, while all relevant fundamentals were already developed in the first two funding periods. In the third phase of the given research project, the focus will lie on the implementation of the property-controlled free-form bending process with a moving die in real time with continuous feed under production conditions. Therefore, the soft sensor technology and the control system will be embedded in the machines control system, and the overall control loop will be investigated experimentally. Subsequently, the proof of the positive effect of the property control for free-form bent components is demonstrated using a test rig and experiments. Furthermore, the soft sensor-based property control methodology will be applied to more complex component geometries as well as other materials (e.g., ferritic stainless steel or higher-strength steel) and analyzed scientifically. The research project will conclude in deriving generally applicable design principles for the property-controlled free-form bending process.