Optimization of Tooling Design for Hot Mandrel Bending of Pipe Elbows

<jats:p>This paper presents the finite element model developed for the simulation of pipe elbow production by the so-called ‘Hamburg process’ in order to improve productivity and resource efficiency. To optimize the tooling design, a sensitivity analysis of the tool parameters that influence the quality of pipe elbows, such as mandrel height and length, is conducted. Different materials data sets including damage models were considered. Using numerical simulations, it is possible to determine an optimized tool geometry for the production of specific pipe elbow dimensions. Furthermore, as a result of the experiments and numerical simulations conducted, it is possible to increase the production velocity of the serial plant. Along with deformation, damage models are included in simulations in order to identify the right process boundaries. Finally, an experimentally validated model is developed for increasing resource efficiency in pipe elbow fabrication.</jats:p>