During the metal tube bending (MTB) process, high-fidelity reconstruction of full cross-section (FCS) deformation is critical to the robustness of closed-loop control in tube-bending manufacturing systems. However, the distributed nature of industrial data, the spatiotemporal discontinuity of physical sensing, and the heterogeneity of multimodal physical–virtual data hinder effective integration of distributed sources and precise reconstruction of the transient deformation of tube surfaces. To address these challenges, we propose a Federated Split-Learning–Driven Multimodal Physical–Virtual Integration (FSLD-MPVI) framework. Leveraging a hybrid distributed–centralized architecture with cross-level collaborative fusion, FSLD-MPVI enables efficient integration and knowledge sharing of local high-fidelity visual data, global low-fidelity finite-element (FE) simulation data, and static process parameters that are dispersed across manufacturing nodes. Within the split learning (SL) distributed architecture, three cascaded, heterogeneous subnetworks are deployed, each dedicated to fusing a specific class of hybrid modality inputs, thereby providing the infrastructure needed to integrate modalities originating from different workshops. In the federated learning (FL) layer, a centralized server aggregates the parameters of each subnetwork respectively, mitigating cross-node data isolation while preserving data locality. Experiments demonstrate that FSLD-MPVI achieves high-accuracy global reconstruction (R² = 0.9973); in the 90° bending case, the shape deviation remains within 0.2 mm. These results verify that multimodal physical–virtual integration strongly supports precise global reconstruction of FCS deformation fields and establishes a new paradigm for intelligent process monitoring in advanced manufacturing systems.
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