Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

3 Roll Bending of free-formed tubes and pipelines

Project Status: finished


Bended pipelines find a widespread applica-tion in several industrial sectors. Among different bending processes developed for the manufacture of such components, 3 roll bending is characterized by a high flexibil-ity, as only one toolkit per tube diameter is necessary to form the required bending ra-dius. In this type of bending process the part geometry is obtained by means of a relative movement of the die setting roll towards the fixed tool bending and holding roll with simultaneous feeding of the tube. The research project aims at a better understanding of the three roll bending process. In order to reach this aim, FE-Simulation is used to investigate the forming zone and the parameters affecting it and to quantify the stresses acting in the material and the re-sulting strains. The objective of this work is to realize an FE-based model of the forming process able to set and control the tube bending automatically, predicting the tool setting necessary to achieve the required part geometry and allowing for a relevant reduction of the machine set-up time.

Bending die of the three-roll-push bending machine Crippa CA linear 925 E (left), exemplary freeform bending geometry (right)

Bending die of the three-roll-push bending machine Crippa CA linear 925 E (left), exemplary freeform bending geometry (right)

Research Groups



    • Plettke, R.; Vatter, P.:
      Comparison of new analytical an numerical approaches to model the three-roll-push-bending process.
      Int. J. Mechatronics and Manufacturing Systems 7(2014)4/5/6, pp. 279-295


    • Vatter, P.; Plettke, R.:
      Process model for the design of bent 3-dimensional free-form geometries for the three-roll-push-bending process.
      Procedia CIRP 7(2013), pp. 240-245

    • Vatter, P.; Plettke, R.; Merklein, M.:
      New approaches to determine the bending contour of the 3-roll-push-bending process.
      In: Kaftanoglu, B. (Edtr.): 7th Int. Conf. on Design and Production of Machines and Dies/Molds, MATIM, 2013, pp. 71-76

    • Vatter, P.; Plettke, R.:
      Geometrical variations of tubes and their impact on freeform bending processes.
      Adv. Mater. Res. 769(2013), pp. 181-188


    • Plettke, R.; Vatter, P.; Vipavc, D.:
      Basics of process design for 3d freeform-bending.
      Steel Res. Int. (2012), pp. 307-310

    • Merklein, M.; Vatter, P.; Plettke, R.; Grüner, M.:
      Einfluss der Fließkurve auf den Rohrbiegeradius.
      Werkstattstechnik online 10(2012), pp. 689-695


    • Plettke, R.; Vipavc, D.; Vatter, P.:
      Influence factors of three-roll-push-bending.
      In: Tekkaya, A. E. (Edtr.): Proc. 1st Int. Tube and Profile Bending Conf., 2011, pp. 131-135


    • Plettke, R.; Vatter, P.; Vipavc, D.; Cojutti, M.; Hagenah, H.:
      Investigation on the Process Parameters and Process Window of "Three-Roll-Push-Bending".
      In: Hinduja, S.; Li, L. (Edtrs.): Proc. 36th Matador Conf., Springer, 2010, pp. 25-28

    • Hagenah, H.; Vipavc, D.; Vatter, P.; Cojutti, M.; Plettke, R.:
      Creation of the Data Base for the Process Design of the Three-Roll-Push Bending Process.
      In: Teti, R. (Edtr.): 7th CIRP Int. Conf. Intelligent Computation in Manufacturing Engineering, 2010, pp. 259-264

    • Hagenah, H.; Vipavc, D.; Plettke, R.; Merklein, M.:
      Numerical Model of Tube Freeform Bending by Three-Roll-Push-Bending.
      In: Associacao Portuguesa de Mecanica Teória, Aplicada e Computacional (Edtrs.): 2nd International Conference on Engineering Optimization, 2010, published on CD


    • Cojutti, M.; Vipavc, D.; Hagenah, H.; Merklein, M.:
      An innovative approach for the process design for three-roll bending of plain tubular components.
      In: Angeles Gutierrez, M.; Sedlmaier, A.; Galdós, L. (Edtrs.): Proc. 1st Int. Congress on Roll Forming, 2009, pp. 133-139

    • Merklein, M.; Hagenah, H.; Cojutti, M.:
      Investigations on Three-Roll Bending of Plain Tubular Components.
      Key Eng. Mater. 410-411(2009), pp. 325-334


    • Merklein, M.; Geiger, M.; Hagenah, H.; Cojutti, M.:
      3-Rollen-Schubbiegen zur flexiblen Herstellung freiformgebogener Rohrleitungen.
      Zukunftstechnologien in Bayern (2008), pp. 24-26

    Letztes Update: 27.02.2014