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Optimization of the Design and Manufacturing Process of Bent Profiles

The application of bent aluminum and steel profiles in transportation systems has increased in recent years. Due to the fierce competition in this area, particularly in automotive construction, a cost-effective design and manufacturing of profile structures is necessary. Furthermore, the total cost of the product can be reduced by a high bending quality (accurate radii distribution, minimal cross-sectional deformations) because the effort for subsequent production steps like assembly and welding depends directly on the afore achieved profile quality. In this paper, the integration of the design and planning phases in a computer based design cycle and two closed-loop process control systems for three-roll-bending are presented as parts of a design and manufacturing system for structures made of bent profiles.