Advertisement

Research on influencing factors and laws of free-bending forming limit of tube

  • 49 Accesses

Abstract

For the free-bending forming of complex bending components, the forming limit significantly influences the complexity of the forming materials. In this study, the wrinkle factor Iw, which comprehensively affects the forming limit of free-bending, was obtained by theoretical analysis. The process parameters affecting the forming limit of free-bending were systematically studied by using the ABAQUS finite element simulation platform. Moreover, the effects of series of parameters on the relationship curve and wrinkling factor under different eccentricity conditions were also analyzed. The free-bending forming limit under the optimal conditions was obtained, which provides a process optimization method to improve the forming limit for practical test and production. Furthermore, the forming experiments were conducted on tubes with different wall thickness, and it was verified that the wall thickness factors significantly influenced the forming limit of the tubes. Finally, the forming experiments were carried out on 6061-T6 aluminum alloy, H2 copper, and H62 brass tubes. The results proved that the yield strength was the key material parameter affecting the forming limit of metal tubes.

This is a preview of subscription content, log in to check access.

Access options

Buy single article

Instant unlimited access to the full article PDF.

US$ 39.95

Price includes VAT for USA

Subscribe to journal

Immediate online access to all issues from 2019. Subscription will auto renew annually.

US$ 199

This is the net price. Taxes to be calculated in checkout.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

References

  1. 1.

    Tao Z, Fan X, Yang H, Ma J (2018) A modified Johnson-Cook model for NC warm bending of large diameter thin-walled Ti-6Al-4V tube in wide ranges of strain rates and temperatures. Trans Nonferrous Metals Soc China 28(2):298–308

  2. 2.

    Zhang H, Liu Y, Yang H (2017) Study on the ridge grooves deformation of double-ridged waveguide tube in rotary draw bending based on analytical and simulative methods. J Mater Process Technol 243:100–111

  3. 3.

    Murata M, Kuboki T (2015) CNC tube forming method for manufacturing flexibly and 3-dimensionally bent tubes. In: 60 Excellent Inventions in Metal Forming. Springer, Berlin Heidelberg, pp 363–368

  4. 4.

    Xiong H, Ma Y, Zhou S, He Y, Yang X, Jin K, Wang H, Luo X, Guo X (2018) Free bending forming technology of three dimensional complex axis hollow component. J Plasticity Eng 25(1):100–110

  5. 5.

    Beulich N, Craighero P, Volk W (2017) FEA simulation of free-bending- a preforming step in the hydroforming process chain. J Phys Conf Ser 896

  6. 6.

    Zhou Y, Li P, Li M, Wang L, Sun S (2018) Residual stress and springback analysis for 304 stainless steel tubes in flexible-bending process. Int J Adv Manuf Technol 94(1–3):1317–1325

  7. 7.

    Guo X, Jin K, Wang H, Pei W, Ma F, Tao J (2016) Numerical simulations and experiments on fabricating bend pipes by push bending with local induction-heating process. Int J Adv Manuf Technol 84(9):2689–2695

  8. 8.

    Wu J, Zhang Z, Shang Q, Li F, Wang Y, Hui Y, Fan H (2017) A method for investigating the springback behavior of 3D tubes. Int J Mech Sci 131-132:191–204

  9. 9.

    Guo X, Xiong H, Li H, Xu Y, Ma Z, El-Aty A, Ma Y, Jin K (2018) Forming characteristics of tube free-bending with small bending radii based on a new spherical connection. Int J Mach Tool Manu 133:74–82

  10. 10.

    Gantner P, Bauer H, Harrison D, Silva A (2005) Free-bending—a new bending technique in the hydroforming process chain. J Mater Process Technol 167:302–308

  11. 11.

    Guo X, Xiong H, Xu Y, El-Aty A, Ma Y, Zhao Y, Zhang S (2018) U-R relationship prediction method for aluminum alloy circular tube free-bending process based on sensitivity analysis of material parameters. Int J Adv Manuf Technol 99(5–8):1967–1977

  12. 12.

    Gantner P, Harrison D, Silva A, Bauer H (2007) The development of a simulation model and the determination of the die control data for the free-bending technique. P I Mech Eng B-J Eng 221(2):163–171

  13. 13.

    Murata M, Ohashi N, Suzuki H (1989) New flexible penetration bending of a tube : 1st report, a study of MOS bending method. Trans Japan Soc Mech Eng C 55:2488–2492

  14. 14.

    Guo X, Ma Y, Chen W, Xiong H, Xu Y, El-Aty A, Jin K (2018) Simulation and experimental research of the free bending process of a spatial tube. J Mater Process Technol 255:137–149

  15. 15.

    Murata M (1996) Effects of inclination of die and material of circular tube in MOS bending method. Trans Japan Soc Mech Eng 62(601):3669–3675

  16. 16.

    Murata M (1996) Analysis of circular tube bending by MOS bending method. Proc. 5th ICTP :505-508

  17. 17.

    Li P, Wang L, Li M (2016) Flexible-bending of profiles and tubes of continuous varying radii. Int J Adv Manuf Technol 88(5–8):1–7

  18. 18.

    Huang K, Lu M, Xue M (1988) Theory of thin shells. Higher Education Press

  19. 19.

    Yang H, Lin Y (2004) Wrinkling analysis for forming limit of tube bending processes. J Mater Process Technol 152(3):363–369

  20. 20.

    Li H, Yang H, Zhan M (2009) A study on plastic wrinkling in thin-walled tube bending via an energy-based wrinkling prediction model. Model Simul Mater Sc 17(17):35007–35039

  21. 21.

    Peek R (2002) Wrinkling of tubes in bending from finite strain three-dimensional continuum theory. Int J Solids Struct 39(3):709–723

  22. 22.

    Kawasumi S, Takeda Y, Matsuura D (2014) Precise pipe-bending by 3-RPSR parallel mechanism considering springback and clearances at dies. Transactions of the Japan Society of Mechanical Engineers 80:TRANS0343-TRANS0343

  23. 23.

    Guo X, Xiong H, Xu Y, Ma Y, El-Aty A, Tao J, Jin K (2018) Free-bending process characteristics and forming process design of copper tubular components. Int J Adv Manuf Technol 96(9–12):3585–3601

Download references

Author information

Correspondence to Xunzhong Guo.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Wei, W., Wang, H., Xiong, H. et al. Research on influencing factors and laws of free-bending forming limit of tube. Int J Adv Manuf Technol 106, 1421–1430 (2020) doi:10.1007/s00170-019-04692-0

Download citation

Keywords

  • Free-bending
  • Forming limit
  • Wrinkle factor
  • Process parameters
  • Material parameter