Shape Prediction and Improvement for Canning of Non-Round Tubes

The reduction of CO₂ emissions requires an improved scrap rate during production. For this purpose, the forming process chain (calibrating and end forming, see figure) and the deformation due to the insertion of a coated ceramic (canning, see figure) of non-round exhaust components were numerically examined in this project. One challenge was the consideration of unknown or variable process parameters in the simulation. The implementation of mechanical forming in the software was developed to predict the resulting shape with respect to the required accuracy. Numerical modeling of the subsequrent canning process was set up with a representive pressure due to the large tolerances during manufacturing. This pressure can be determined from given measurement data and imposed in the FEM software using a specially developed program. Using this approach, the influence of the canning process is now predictable with the desired accuracy.