Kinematic Tool-Bound Profile Bending using Transformer-Tools

该项目的总体目标是通过就地调整刀具工作面，增加工具约束型材弯曲过程的灵活性，使之成为部分运动性过程，工具工作面由主动的、可变的桁架状网格结构产生。除了传感器、执行器和控制系统的必要发展外，首先要研究与工具设计有关的机械问题。这些重点是拟议项目的核心，在该项目中，两个提出者正在就互补的主题开展工作。第一个提出者涉及刀具工作面，目的是研究分段表面的几何设计方法，包括尺寸和几何以及分段之间的间隙和肩部的布置。为此，将在项目范围内研究分段对局部变形行为的影响以及基于局部作用法向应力和弯曲应力产生的闭合轮廓的全局变形行为。每个刀具段被理解为一个潜在的致动器，不仅允许曲面轮廓的重大变化，而且还允许刀具约束和部分运动学设计的局部调整。因此，进一步的目的是研究修整刀具表面的机理，作为就地调整的基础。基于对传统闭合刀面回转拉伸弯曲过程中局部作用应力的分析，推导出了一种分段刀面弯曲形状的生成方法，该方法可以产生局部和时间可变的弯曲半径，因此刀具结构必须能够诱导这些时变和位置可变的分段位移，同时从成形过程中获得载荷。在这一总体目标下，人们正在探索新的形状和拓扑优化方法，以模拟如何使用混合整数优化(MIP)来找到这样的杆件结构工具设计。该方法的核心是从大量的可能性中提取基于模型的解决方案，这些可能性导致在工程实践中使用功能工具，但在模型中是近乎最优的。结合两个提出者开发的方法，将结果汇集在联合工作包中。其目的是开发一种弯曲工具的设计方法，该方法将成形相关的边界条件与确定桁架状点阵结构的算法相结合。最后，这些结果将导致变压器工具的功能模型，将用于验证所开发的设计方法，并显示可能的技术概念。

The overall objective of this project is to increase the flexibility of tool-bound profile bending processes to partially kinematic processes trough in-situ adjustment of tool working surfaces, which are generated by active, variable truss-like lattice structures. In addition to the necessary development of sensors, actuators and control systems, mechanistic issues regarding the tool design are to be investigated first. These focus the core of the proposed project, in which the two proposers are working on complementary topics. The first proposer deals with the tool working surfaces aiming for researching methods for the geometric design of segmented surfaces with respect to size and geometry alongside to the arrangement of gaps and shoulders between the segments. For this purpose, the effect of the segmentation on the local deformation behaviour as well as the resulting global deformation behaviour of closed profiles based on the locally acting normal and bending stress, will be investigated in the scope of the project. Each tool segment is understood as a potential actuator, not only allowing a major change of the surface contour, but also the local adjustment of tool-bound and partially kinematic design. Therefore, a further aim is to investigate mechanisms for modifying the shaping tool surfaces as a basis for in-situ adjustment. Based on an analysis of the local acting stresses during rotary draw bending with conventionally closed tool surfaces, finally a method for the generation of bending shapes with segmented tool surfaces is derived, with which a locally and temporally variable bending radius can be produced.The tool structure, which is the research aim of the second proposer, must consequently be able to induce these time- and location-variable segment displacements and simultaneously derive the loads from the forming process. With this overarching goal, new shape and topology optimization methods are being explored to model how to find such a rod structured tool design using mixed integer optimization (MIP). The core of the methodology is to extract model-based solutions from a large number of possibilities, which lead to functional tools in engineering practice, but are near-optimal within the models. Combining the methods developed by both proposers, the outcomes are brought together in the joint work packages. The aim is to develop a design method for bending tools that couples the forming-related boundary conditions with the algorithms for determining the truss-like lattice structure. Concluding, these results will lead to functional models of transformer-tools, which will been used to validate the developed design method and to show possible technical concepts.