Free-bending process characteristics and forming process design of copper tubular components

Guo, Xunzhong; Xiong, Hao; Xu, Yan; Yan, Ma; El-Aty, Ali Abd; Tao, Jie; Jin, Kai

doi:10.1007/s00170-018-1788-1

Cited by 23 publications

(9 citation statements)

References 14 publications

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“…In their study considering the slab method, they obtained stress and strain distribution in the bend section and showed that in areas at the beginning and the end of the bend, they were more intense and non-uniform stress and strain distribution. Guo et al 17 analytically investigated the effect of machine adjustment and control parameters on the material correction factor (K m ) and the coefficient of clearance (K c ) in bending of the Copper tube using a spherical connection of the bending die to the guider. They showed that proper selection of tube feed speed, clearance coefficient, material coefficient, and adjustment parameters of the machine plays an essential role in producing highquality bent tubes.…”

Section: Introductionmentioning

confidence: 99%

The effects of loading path on process parameters in the free tube forming process

Mosavi

Mazdak

Sheykholeslami

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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The free bending method is the simplest method among the tube bending processes without the use of a die. Despite the simplicity of the process, there is no proper control over the geometrical tolerance of the product. The loading path or in other words the bearing movement mechanism is one of the effective factors on product geometry. In this paper, a finite element simulation has been carried out to investigate two different bearing movement time-paths (synchronous and asynchronous mechanisms); then, the results have been verified with experimental tests. The thickness distribution in different directions, ovality, bending radius, and applied forces on the bearing and the tube for both bearing movement mechanisms are the main results of this paper. The amplitude of thickness change in both mechanisms was equal. But there is a uniform trend in variation of thickness distribution in synchronous mechanisms. So, better geometrical quality of products is expected in this mechanism. On the other hand, because of uniform force distribution with tube movement in the bearing and tube, the stability of the asynchronous mechanism is higher than the synchronous mechanism.

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Section: Introductionmentioning

confidence: 99%

The effects of loading path on process parameters in the free tube forming process

Mosavi

Mazdak

Sheykholeslami

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…The new bending technology inherits the high flexible characters in the traditional push bending process. Without changing tools, different bending curvatures and bending angles can be obtained easily [7][8][9]. Besides, the free bending technology extends the forming scope of the push bending process greatly.…”

Section: Introductionmentioning

confidence: 99%

Trajectory Prediction of Three Dimensional Forming Tube Based On Kalman Filter

Yang

2021

Preprint

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This article focuses on the prediction of forming trajectory and process optimization during the forming process for the variable curvature tubes. Firstly, through cubic B-spline interpolation, the geometric characteristics of the axis of the target tube are obtained. An overall tube is "separated and then integrated", and the relationship between geometric parameters and processing parameters is established to obtain the initial process parameters. Based on the Extended Kalman Filter (EKF) algorithm, the motion model and observation model of tube forming using simulation are presented section by section, and the relevant calculation and analysis are carried out. The forming trajectory has been predicted and the processing parameters are optimized during the processing process, in which the effectiveness of the processing optimum scheme is illustrated.

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“…Based on this background, the free bending forming (FBF) technology was firstly proposed in Japan by Murata et al in 1990 [17], and the prototype of a free bending machine was developed in 1993 [18]. Without changing the bending die and re-clamping the target tube [3], the tubes [19], profiles [20], and wires [21] with bend-in-bends or with continuous varying radii even possibly also with twisting can be manufactured precisely and efficiently by free bending forming (FBF) technology [22,23].…”

Section: Introductionmentioning

confidence: 99%

“…They lowered the relative bending radius to R/D 0 = 2.5. Furthermore, the impact of the material parameters (copper tubular components [22], Cu-Al bimetallic tube [28]), process parameters (clearance between tube and bending die, fillet radius of the guider and feeding speed) [23], and different filling material [19] on the formability and crosssection distortion have been investigated. Some researchers began to pay attention to the free bending process of hollow profile tubes.…”

Section: Introductionmentioning

confidence: 99%

Deformation behavior of convolute thin-walled AA6061-T6 rectangular tubes manufactured by the free bending forming technology

Cheng

Zhao

El-Aty

et al. 2021

Int J Adv Manuf Technol

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During manufacturing thin-walled tubes using free bending forming (FBF) technology, defects such as wrinkling, cracking, and cross-section distortion are easy to exist due to various forming parameters' direct and indirect influence, which seriously influences the forming quality of the rectangular tubes. Thus, in this study, the finite element (FE) modeling of thin-walled AA6061-T6 rectangular tubes manufactured by FBF technology was accomplished and verified through experimentation. Moreover, the influence of different parameters on the deformation behavior of the rectangular tubes was systematically investigated using FE modeling. The results showed that the maximum thickness changing rate and the cross-section distortion appeared once the bending die moved to the maximum eccentricity (U max ). Besides, with the increase of yield strength-Young's modulus ratio (σ s /E), thickness (t 0 ), fillet radius (R f ), clearance (Δc), friction coefficient (f), and chamfer radius of the guider (R c ), the thickness changing rate and the cross-section distortion decrease, while the bending radius enlarges simultaneously when the parameters are set within reasonable limits. Unlike the above parameters, with the improvement of the axial feeding speed (V f ), the thickness changing rate declines while the fluctuation of bending radius is not significant. Under the joint action of the axial force P L , the structural characterization of the rectangular tube and the dies of constraints, the thinning of the outer wall and the web distortion are inhibited, and the variation amplitude of them is much smaller than that of thickening of the inner wall and flange distortion during the free bending process.

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Free-bending process characteristics and forming process design of copper tubular components

Cited by 23 publications

References 14 publications

The effects of loading path on process parameters in the free tube forming process

The effects of loading path on process parameters in the free tube forming process

Trajectory Prediction of Three Dimensional Forming Tube Based On Kalman Filter

Deformation behavior of convolute thin-walled AA6061-T6 rectangular tubes manufactured by the free bending forming technology

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