Process-integrated Compensation of Geometrical Deviations for Bulk Forming

Abstract In many cases the design and development of bulk forming processes bases on inefficient trial-and-error procedures consisting of various iterations of numerical and real tests. To address this issue, a new numerical strategy to compensate systematic deviations of bulk-formed parts is deduced. Due to a parameter-based approach, control points allow for a direct mapping between the die and the workpiece. Thus, based on the required part shape, it is possible to directly adjust the die, where any kind of geometrical input data can be provided to derive a systematic compensation. The purely geometrical approach takes into account the entirety of systematical effects regarding deviations in bulk forming. The proposed concept is shown theoretically and moreover validated as well as verified utilizing deviation data of three manufactured industrial bulk-forming parts.