An analytical model for the collapsing deformation of thin-walled rectangular tube in rotary draw bending

Liu, K. X.; Liu, Y. L.; Yang, He

doi:10.1007/s00170-013-5042-6

Cited by 13 publications

(3 citation statements)

References 20 publications

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“…Fox et al [18] conducted a test on the friction coefficient of sheet drawing and forming and established a mathematical model to describe the friction coefficient under different contact conditions. Liu et al [19][20][21] found an analytical model for rotational tensile bending section deformation of thin-walled rectangular tubes and studied the effects of die constraint and interfacial friction on section deformation. The best combination of friction coefficient and minimum cross-sectional distortion was obtained by the rotary draw bending process tests.…”

Section: Introductionmentioning

confidence: 99%

Influence of Contact Interface Friction on Plastic Deformation of Stretch-Bend Forming

Zhang

et al. 2022

Coatings

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The contact interface friction between the specimen and the mold during the stretch-bend is a complex interactive process. Friction causes the uneven distribution of tensile stress on the specimen, which affects the plastic flow of the forming material and the spring-back after forming. In this paper, the analytical model of frictional shear stress and tensile stress distribution in the contact mold segment of the stretch and bend synchronous loading stage was established. The influence law of friction coefficient and contact mold angle on the stress–strain distribution of the specimen contact mold segment was discussed. The effect of key factors affecting the friction state of the contact interface (mold surface roughness and contact mold angle) on the shrinkage deformation of the cross-section and the tensile deformation gradient of the specimen was analyzed by equivalent stretch-bend forming experiments. The results showed that the smaller the surface roughness of the mold was, the better the friction state of the contact interface was, the plastic deformation of the specimen was more uniform, and the difference between the section shrinkage and elongation of the contact mold segment and the suspension segment was smaller. Reducing the contact mold angle of the stretch-bend can bring down the tensile stress difference at both ends of the contact mold segment of the specimen so that the section shrinkage and tensile elongation of the contact mold segment and the suspension segment tend to be consistent.

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Section: Introductionmentioning

confidence: 99%

Influence of Contact Interface Friction on Plastic Deformation of Stretch-Bend Forming

Zhang

et al. 2022

Coatings

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“…After that, Kim and Reid 33 presented a self-consistent method to analytically derive the bending collapse characteristics of rectangular tubes. Afterwards, various bending collapse characteristics were derived, such as circular, 34,35 square, 36,37 triangular, 38 channel, 39 multi-corner and multi-cell, 40 which are validated via experimental or numerical methods.…”

Section: Introductionmentioning

confidence: 99%

Bending collapse of treble rectangular thin-walled tubes and its application in conceptual design for automobile crashworthiness

Tian²,

Bai

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part D:

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The aluminium profiles of treble rectangular thin-walled tubes (TRTWT) manufactured by extrusion processes are extensively applied in energy absorption structures of automobile due to the high crashworthiness and stiffness-to-mass ratio. Therefore, this paper investigates the bending collapse characteristics of the TRTWT and its application in conceptual design for automobile crashworthiness. Firstly, the bending collapse behaviours of the TRTWT are obtained through experimental method. Then, the analytical expressions for the bending collapse characteristics are derived in detail by using the global energy equilibrium theory, which are validated by comparing with experimental and numerical results. Furthermore, the bending collapse characteristics are applied in the simplified model to conduct crashworthiness analysis and optimization for the conceptual design of the automobile with the TRTWT, which can enhance the crashworthiness and greatly shorten design cycle. Finally, application examples for the front-end and side-wall structures of automobile demonstrate that the simplified model with the analytical bending collapse characteristics can be used as a substitute of detailed model for accelerating crashworthiness design of the automobile with the TRTWT.

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“…Based on this deformation characteristic, it is necessary to clarify the optimal processing conditions for deforming the cross-section of the channel material to several cross-sectional shapes, such as domes or hats, and to simultaneously impose the desired curvature on them [5]. Therefore, in this study, we have designed a simulation model [6] for the rotary draw bending process [7] for aluminum alloy channel materials without tensile flanges. The effects of bend angle and workpiece thickness on the cross-sectional deformation were then examined.…”

Section: Introductionmentioning

confidence: 99%

Development of Forming Method for Aluminum Alloy Channel with Curvature and Modified Cross-Section Shape in Rotary Draw Bending

Ito

Utsumi

Yoshida

2015

AMR

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In the manufacturing industry, metal cross-sections and profiles are manufactured by using extrusion as the primary process. Subsequently, the products are generally subjected to bending in a secondary process. However, long products with the same cross-sections are typically mass-produced by one extrusion. In industries that manufacture such products, there have been increasing demands for flexible manufacturing systems that can be used for low-volume diverse products. However, it is difficult to adapt traditional manufacturing systems to this requirement. In this study, we aimed to develop a new bending method that can be used to deform the cross-sections of existing versatile extruded sections, such as channel materials and rectangular tubes, to several types of cross-sectional shapes and to simultaneously impose a desired curvature on them. The rotary draw bending process for an aluminum alloy channel material without tensile flanges was investigated by using the finite element method and experiments. The effects of the bend angle and thickness ratio on the cross-sectional deformation were examined. Furthermore, the influence of additional axial tension on the channel materials was studied. Additional axial tension can be used to control the outward and inward deformations of the webs. In addition, it was confirmed that the axial tension is very effective in preventing wrinkling and folding.

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An analytical model for the collapsing deformation of thin-walled rectangular tube in rotary draw bending

Cited by 13 publications

References 20 publications

Influence of Contact Interface Friction on Plastic Deformation of Stretch-Bend Forming

Influence of Contact Interface Friction on Plastic Deformation of Stretch-Bend Forming

Bending collapse of treble rectangular thin-walled tubes and its application in conceptual design for automobile crashworthiness

Development of Forming Method for Aluminum Alloy Channel with Curvature and Modified Cross-Section Shape in Rotary Draw Bending

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