Virtual Try Out and Process Optimization for an Innovative Conic Poles Production Concept

This paper describes how the production Process for conic poles has been reviewed in order to provide innovative solutions for the forming process which has been considered the most critical operation. Finite Element Analysis using an explicit code has provided a virtual way to investigate possible solutions evaluating advantages or disadvantages before that any prototype tool has been developed. More than one solution was possible, FEA has given the chance to evaluate the more promising one which was based on a different forming philosophy, that is the usage of profiling forming, which has an innovative aspect if it is applied on conic shapes like in this case. Tools shapes and process parameters were tuned through a massive usage of numerical simulations. The defined innovative solution allows to cut the production times of a considerable amount with an higher quality for the final product.