Investigation of tube fracture in the rotary draw bending process using experimental and numerical methods

Safdarian, R.

doi:10.1007/s12289-019-01484-5

Cited by 26 publications

(11 citation statements)

References 30 publications

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“…Many authors have dealt with the phenomenon of the tool modification in the past, e.g. [3], [4] or [9]. This approach represents a potential for improvement, which is not so much used in practice yet.…”

Section: Tube Ovalitymentioning

confidence: 99%

“…1. [3] Fig. 1 Basic principle of RDB The pressure die can be firmly fixed in place during the forming process or move alongside with the bent tube.…”

Section: Introductionmentioning

confidence: 99%

“…RDB has gained more applications in automotive industries or aerospace thanks to its wide possibilities. [3], [4] The main technological problem in the tube bending lies in forming of the hollow part, which increases the problems in the form of defects. The occurrence of defects is an inevitable phenomenon in practice.…”

Section: Introductionmentioning

confidence: 99%

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Improving Rotary Draw Bending Process by Changing a Geometry of the Pressure Bar

Rihacek¹,

Peterkova²,

Císařová³

2021

Manufacturing Technology

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The paper is focused on an analysis and optimization of the rotary draw bending process to eliminate bent tube ovality by modification of the pressure die geometry. The bending process is realized on Wafios CNC bending machine. A tube that is bent for an automotive application is made of 34MnB5 steel. Currently, after tube bending process by an angle of 120°, an unacceptable ovality occurs. Therefore, it is necessary to improve the quality of production and thus prevent the formation of unacceptable ovality. In this case, the optimization of the pressure die geometry is carried out. For this reason, a numerical simulation using finite element method in ANSYS software is performed. Before the actual optimization, an accuracy of the simulation is verified by analysing of the current state and comparing it with simulation results.

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Section: Tube Ovalitymentioning

confidence: 99%

“…1. [3] Fig. 1 Basic principle of RDB The pressure die can be firmly fixed in place during the forming process or move alongside with the bent tube.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Improving Rotary Draw Bending Process by Changing a Geometry of the Pressure Bar

Rihacek¹,

Peterkova²,

Císařová³

2021

Manufacturing Technology

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“…The virtual damage initiation and evolution (when and where the ductile fracture occurs) in thin-walled tube bending were investigated, and the fracture mechanisms of the voided Al-alloy tube in tube bending were consequently discussed. Safdarian [10] applied the Gurson-Tvergaard-Needleman damage model to a numerical simulation of rotary draw bending for fracture prediction in a BS3059 steel tube, and studied the effect of the pressure of pressure die, boosting velocity of pressure die, friction between the tube and pressure die, mandrel position and number of mandrel balls on the fracture, wrinkling, and the tube's ovality.…”

Section: Introductionmentioning

confidence: 99%

Research on Hydraulic Push-Pull Bending Process of Ultra-Thin-Walled Tubes

Zhang

Zhao

et al. 2021

Metals

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Due to their high strength, high performance, and lightweight characteristics, bent tubes are widely used in many high-end industries, such as aviation, aerospace, shipbuilding, automobile, and petrochemical industries. Ultra-thin-walled (thickness-to-diameter ratio t/D < 0.01) bent tubes are more prone to wrinkling, fracture, and cross-section distortion than ordinary bent tubes, which are difficult to form integrally by traditional bending processes. In this paper, a new bending process with combined loading of hydraulic pressure, push, and pull was proposed to provide a new method for the bending of ultra-thin-walled tube. This process is characterized by the ability to optimize the combination of push, pull, and internal pressure according to the actual bending process in order to minimize the wrinkling of ultra-thin-walled tube during bending. Based on ABAQUS finite element (FE) software, the FE model of the hydraulic push-pull bending process for ultra-thin-walled tube was established. The influence of internal pressure, die clearance, and friction coefficient on the forming quality of bent tubes was discussed, and the optimum process parameters were obtained. Bent tubes with an initial thickness of 0.3 mm, diameter of 60 mm, and bending radius of 165 mm were manufactured in experiments. Through the comparative analysis of experiment and simulation, the accuracy of the FE simulation was verified.

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“…[19] Three-dimensional finite element modeling of rotary-draw bending of copper-titanium composite tube. [20] Investigation of tube fracture in the rotary draw bending... [21] Springback angle prediction of circular metal tube considering the interference of cross-sectional distortion in mandrel-less rotary draw bending. [22] Analysis of the Rotary-draw Bending Process for Thin-walled Rectangular Aluminum Tube.…”

mentioning

confidence: 99%

Experimental and Numerical Study of Rotational Draw Bending Process of SS-304 Thin-walled Pipes Using Polyurethane and NBR Mandrels

Ghahreman

Honarpisheh²,

Sarafrazi³

2022

Modares Mechanical Engineering

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One of the methods of forming pipes is the rotary draw bending process. Today, the bending of thin-walled pipes with a low radius of curvature is widely used in the automotive, military, and aerospace industries. This process is used to bend high-strength pipes. In this paper, at first, the necessary models were created to simulate the bending process of the rotary pipe. Then, the mechanical and physical properties of stainless steel 304 and elastomers were determined. Then, the forming force and changes in pipe wall thickness were experimentally and numerically measured. The process simulation was analytically performed by polyurethane elastomeric and nitrile rubber mandrels in ABAQUS finite element software. The results show a good agreement between simulation and experimental results. Finally, the effects of process parameters including mandrel type, pipe diameter, and bending radius were analyzed on the maximum forming force by factorial analysis. The results showed that the maximum forming force for both types of mandrel materials obtain for pipes with small diameter and high curvature radius. Also, the bending forces increase 5 times by 30% increasing the bending radius, for pipes with smaller diameters. In addition, in equal diameter and radius of bending, the bending forces in the case of using polyurethane mandrel are 25% more than nitrile mandrel.

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Investigation of tube fracture in the rotary draw bending process using experimental and numerical methods

Cited by 26 publications

References 30 publications

Improving Rotary Draw Bending Process by Changing a Geometry of the Pressure Bar

Improving Rotary Draw Bending Process by Changing a Geometry of the Pressure Bar

Research on Hydraulic Push-Pull Bending Process of Ultra-Thin-Walled Tubes

Experimental and Numerical Study of Rotational Draw Bending Process of SS-304 Thin-walled Pipes Using Polyurethane and NBR Mandrels

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