Hybrid tools for tube bending processes using additive manufacturing and digital twin

Hybrid tools for tube bending processes using additive manufacturing and digital twin | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Hybrid tools for tube bending processes using additive manufacturing and digital twin Muhammad Ali Kaleem, Peter Frohn-Sörensen, Rainer Steinheimer, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8040156/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Apr, 2026 Read the published version in International Journal of Material Forming → Version 1 posted You are reading this latest preprint version Abstract Forming tools are conventionally made from alloy steels with high material stiffness (Elastic Modulus). In comparison to alloy steels, polymeric materials are light weight and inexpensive. 3D printed polymeric tools are therefore suitable for manufacturing setups oriented towards customized productions. However, relatively low material stiffness limits the use of polymeric tools in production regime. This paper presents a novel concept of developing hybrid tools which consists of highly stiff metallic surfaces and 3D printed polymeric base. The hybrid tools are designed according to process parameters, tool material properties and contact pressure pattern at the tool’s mating surfaces. The contact surfaces of a hybrid tool behave like actuators which respond according to pre-computed applied loads. As test case, a hybrid forming tool (hybrid pressure die) is designed, developed and tested in a cold form tube bending process. FE-simulations are conducted with the digital twin of the tube bending process. The accuracy of digital twin is validated by conducting practical experiments. A comparison is made between hybrid pressure die and its erstwhile conventional counterpart (metal pressure die). Performance comparison is based on von Mises stresses, major strains, contact forces, failure risk, elastic deformations and surface displacements of the tools. Cost comparison is made on the basis of Ashby cost performance index. For the first time, a concept of in-process adjustment of tool surfaces in response to increasing tube diameter is presented. This research demonstrates that hybrid tools are cost effective and light weight alternative to conventional metallic tools used in production processes. Tool Design Forming Tools Hybrid Tools Rotary Draw Bending Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 22 Apr, 2026 Read the published version in International Journal of Material Forming → Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8040156","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":547177169,"identity":"82749aa8-e741-48b6-a386-46693bad627f","order_by":0,"name":"Muhammad Ali Kaleem","email":"","orcid":"","institution":"University of Siegen","correspondingAuthor":false,"prefix":"","firstName":"Muhammad","middleName":"Ali","lastName":"Kaleem","suffix":""},{"id":547177171,"identity":"c4cdfe69-2efe-42ec-a954-1e25edae07ad","order_by":1,"name":"Peter 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twin","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Tool Design, Forming Tools, Hybrid Tools, Rotary Draw 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In comparison to alloy steels, polymeric materials are light weight and inexpensive. 3D printed polymeric tools are therefore suitable for manufacturing setups oriented towards customized productions. However, relatively low material stiffness limits the use of polymeric tools in production regime. This paper presents a novel concept of developing hybrid tools which consists of highly stiff metallic surfaces and 3D printed polymeric base. The hybrid tools are designed according to process parameters, tool material properties and contact pressure pattern at the tool\u0026rsquo;s mating surfaces. The contact surfaces of a hybrid tool behave like actuators which respond according to pre-computed applied loads. As test case, a hybrid forming tool (hybrid pressure die) is designed, developed and tested in a cold form tube bending process. FE-simulations are conducted with the digital twin of the tube bending process. The accuracy of digital twin is validated by conducting practical experiments. A comparison is made between hybrid pressure die and its erstwhile conventional counterpart (metal pressure die). Performance comparison is based on von Mises stresses, major strains, contact forces, failure risk, elastic deformations and surface displacements of the tools. Cost comparison is made on the basis of Ashby cost performance index. For the first time, a concept of in-process adjustment of tool surfaces in response to increasing tube diameter is presented. This research demonstrates that hybrid tools are cost effective and light weight alternative to conventional metallic tools used in production processes.\u003c/p\u003e","manuscriptTitle":"Hybrid tools for tube bending processes using additive manufacturing and digital twin","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-20 13:34:46","doi":"10.21203/rs.3.rs-8040156/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"e028ef0f-d7ff-4b85-a46b-e60921aaef51","owner":[],"postedDate":"November 20th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-04-27T16:08:52+00:00","versionOfRecord":{"articleIdentity":"rs-8040156","link":"https://doi.org/10.1007/s12289-026-02009-7","journal":{"identity":"international-journal-of-material-forming","isVorOnly":false,"title":"International Journal of Material Forming"},"publishedOn":"2026-04-22 15:58:56","publishedOnDateReadable":"April 22nd, 2026"},"versionCreatedAt":"2025-11-20 13:34:46","video":"","vorDoi":"10.1007/s12289-026-02009-7","vorDoiUrl":"https://doi.org/10.1007/s12289-026-02009-7","workflowStages":[]},"version":"v1","identity":"rs-8040156","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8040156","identity":"rs-8040156","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}