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<p>Forming tools (dies, clamps etc.) are conventionally made from alloy steels (X153CrMoV12, EN-1.2379 or AISI-D2) and have a high material stiffness (Elastic Modulus). In comparison with alloy steels, polymeric materials such as polylactic acid (PLA) are light weight and inexpensive. The polymer-based tools are therefore more cost-effective and lightweight and hence suitable for manufacturing setups oriented towards customized production. However, relatively low material stiffness of polymers limits their use as forming tools. This paper presents a novel concept of developing hybrid tools consisting of highly stiff metallic surfaces and 3D printed polymeric base. In this case stainless steel (1.4301) slabs are produced using laser cutting and polylactic acid (PLA) polymeric bases 3D printed using the Additive Manufacturing technique of Fused Filament Fabrication (FFF). The hybrid tools are designed according to process parameters, tool material properties and the contact pressure pattern at the tool’s mating surfaces. The contact surfaces of the hybrid tool behave like actuators which respond according to pre-computed applied loads. This study follows a combined numerical-experimental approach. As a test case, a hybrid forming tool (hybrid pressure die) is designed, developed and tested in a cold form tube bending process. The digital twin of the tube bending process is developed and tool performance is investigated through FE-simulations and it’s accuracy is validated by conducting practical experiments. The focus lies on comparison between the hybrid pressure die and a conventionally used (steel) pressure die. The performance comparison is made based on the von Mises stress, major strain, contact forces, failure risk, elastic deformation and surface displacement at tool surfaces. The cost comparison is made based on the Ashby cost performance index. This study pioneers a concept of in-process adjustment of tool surfaces, in response to continuously increasing tube diameter. The proposed hybrid tools present more cost-effective and lightweight alternatives to conventional metallic tools used in production processes, while also allowing for in-process adaptation.</p>

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Hybrid tools for tube bending processes using additive manufacturing and digital twin

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年4月22日

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  • Muhammad Ali Kaleem,
  • Peter Frohn-Sörensen,
  • Rainer Steinheimer,
  • Bernd Engel

摘要

Forming tools (dies, clamps etc.) are conventionally made from alloy steels (X153CrMoV12, EN-1.2379 or AISI-D2) and have a high material stiffness (Elastic Modulus). In comparison with alloy steels, polymeric materials such as polylactic acid (PLA) are light weight and inexpensive. The polymer-based tools are therefore more cost-effective and lightweight and hence suitable for manufacturing setups oriented towards customized production. However, relatively low material stiffness of polymers limits their use as forming tools. This paper presents a novel concept of developing hybrid tools consisting of highly stiff metallic surfaces and 3D printed polymeric base. In this case stainless steel (1.4301) slabs are produced using laser cutting and polylactic acid (PLA) polymeric bases 3D printed using the Additive Manufacturing technique of Fused Filament Fabrication (FFF). The hybrid tools are designed according to process parameters, tool material properties and the contact pressure pattern at the tool’s mating surfaces. The contact surfaces of the hybrid tool behave like actuators which respond according to pre-computed applied loads. This study follows a combined numerical-experimental approach. As a test case, a hybrid forming tool (hybrid pressure die) is designed, developed and tested in a cold form tube bending process. The digital twin of the tube bending process is developed and tool performance is investigated through FE-simulations and it’s accuracy is validated by conducting practical experiments. The focus lies on comparison between the hybrid pressure die and a conventionally used (steel) pressure die. The performance comparison is made based on the von Mises stress, major strain, contact forces, failure risk, elastic deformation and surface displacement at tool surfaces. The cost comparison is made based on the Ashby cost performance index. This study pioneers a concept of in-process adjustment of tool surfaces, in response to continuously increasing tube diameter. The proposed hybrid tools present more cost-effective and lightweight alternatives to conventional metallic tools used in production processes, while also allowing for in-process adaptation.