Approach to a manufacture-oriented modeling of bent tubes depending on the curvature distribution during three-roll-push-bending

Kinematic bending processes such as three-roll-push-bending are used to manufacture freeform bent part systems. Due to the kinematic shaping, the bent parts have a characteristic infeed and outfeed area in the transition zone from the straight section into the curved area. These transition zones are currently not considered in the design process, which results in a geometric shape deviation between the CAD model and the bent part. Within this publication, a sensitivity analysis examines the influence of different parameters on the transition zone and the shape deviation. In addition, an approach is presented, which allows a manufacture-oriented modeling of the bending geometry.