Incrementel profile forming with stress superposition

Incremental profile forming (IPU) is an advanced forming process for manufacturing tubes with axially varying cross-sections (Figure a). A machine developed for this purpose at the Institute for Forming Technology and Lightweight Construction has a rotating tool head equipped with six radially adjustable tools to specifically influence the cross-section geometry.  This enables the production of semi-finished tubes with adjustable local geometric properties, such as stiffness or further processability. Unfortunately, this process, in a similar way to other kinematic forming processes, results in shape deviations between the programmed tool path (target geometry) and the actual component geometry. These deviations are caused by complex and changing forming mechanisms during the manufacturing process. Therefore, this project investigates additional forces or moments applied during the forming process to determine their influence on the forming zone, the final geometry (Figure c), and the forming mechanisms involved, in order to increase shape accuracy.

Stennei, M.; Gitschel, R.; Tekkaya, A. E.; Korkolis, Y. P., 2025

Influencing forming forces and springback during incremental profile forming using stress superposition.

J. Phys.: Conf. Ser. (Journal of Physics: Conference Series)

https://doi.org/10.1088/1742-6596/3104/1/012038