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Description
High requirements on the CO² emission of cars, lead to the production of new filter systems with complex geometries. In this paper, the effect of manufacturing oval tubular components instead of circular components for the exhaust system is investigated numerically and experimentally. For this purpose, the manufacturing process is divided into the forming process and the stuffing process. In the forming process, the as-delivered tubes are radially expanded in several steps (calibration and endforming). The occurring inhomogeneous strain distributions lead to a complex springback behavior, which results in deviations between the nominal and real geometry.
These shape deviations, the manufacturing tolerances of delivered parts and the non-linear and time-dependent material behavior of the rubber-like components lead to a unique deformation behavior of the components during the last process step (stuffing).
For the numerical analysis of this process, a procedure is presented, which predicts the geometry after the forming process and after stuffing. During the validation of the model, it has been shown that the deviation of the supplied parts must be taken into account in order to predict the final geometry with sufficient accuracy using numerical simulation.