Bent profiles are used in the manufacture of many kinds of products such as transport apparatus and mechanical parts for reduction of production cost and weight. The conventional processes for bent profiles involve a successive extrusion, stretching, and bending of the profiles. Conventional bending methods can not meet demands for precision and cost-effective production in some cases, due to cross sectional deformation, irregular decrease of tube wall thickness and a complication of the process design. There are some researches regarding bending of extruded aluminum profiles during the extrusion process. However, there is no study about the exact prediction of the final various curved profiles. This paper presents the achievements of control of bending tool in the curvature extrusion for a bent profile with various radii. A geometric model, which is the relationship between the bending tool velocity and the extrusion velocity, is proposed to predict the exact geometry of the various curved profile using FE simulation. Experiments were conducted to verify the effectiveness of the proposed geometric model for a vehicle bumper with the various outline radii from 1900mm to 2200mm. The overall correlation between experiments and theoretical results is good. It is, therefore, concluded that the present method provides an efficient means for the variable curvature extrusion process.

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