It is important for the thin-walled tube with relative bending radius of 1 to be bent with mandrel in order to avoid the defects such as wrinkling and cross-section distortion. In this paper, a novel push-bending method using sectional elastomers as mandrel was proposed to form the 5A02 thin-walled aluminum alloy tube with relative bending radius of 1 and 90° bending angle. Cylindrical polyurethane rubber (CPR) with shore hardness of 80A was chosen as the sectional elastomers. The influence of diameter (d), thickness (t), total length (L), and arrangement of CPR filler on the push-bending deformation of tube was first explored by means of simulations and experiments. According to the simulation results, 5A02 thin-walled aluminum alloy tube with relative bending radius of 1 was successfully fabricated with the sectional CPR as mandrel in the self-developed equipment of push-bending. The experimental results were in good agreement with the simulation results. The optimum parameters of CPR filler in push-bending process were obtained as follows: 37 mm diameter, a piece of CPR with 20 mm thickness contacted with the punch, and other 12 pieces of CPR with 10 mm thickness.
Push-bending Sectional polyurethane rubber mandrel Relative bending radius of 1 Thin-walled aluminum alloy tube Finite element simulation Self-developed equipment of push-bending
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This study was financially supported by the National Natural Science Foundation of China with Grant (No. 51405219), the Key R&D Project in Jiangxi Province of China (No. 20165ABC28002), and Project funded by Education Department of Jiangxi Province of China (No. GJJ180531).
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