Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tube

Xue, Xin; Liao, Juan; Vincze, Gabriela; Grácio, J.J.

doi:10.1016/j.jmatprotec.2014.10.007

Cited by 37 publications

(6 citation statements)

References 18 publications

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“…However, similar to sheet metal bending, non-uniform deformation inevitably occurs during bending, viz., tension at the extrados and compression at the intrados of the bending profiles and also a certain degree of twist often occurs during the roll bending process [5,6]. This phenomenon even behaves more obvious for the profiles with asymmetrical section characteristics and can be defined as twist springback or twist defects, which significantly affects the dimensional accuracy and geometrical properties of the product [7][8][9]. As the higher precision requirement in the aerospace industry, it becomes a challenge to efficiently control aluminum alloy twist defects and to accomplish precision forming.…”

Section: Introductionmentioning

confidence: 99%

“…Gangwar et al [13] presented a theoretical analysis for determining springback of arbitrary shaped thin tubular section of materials under torsion loading, in which the residual angle of twist can directly be calculated from the shear stress-strain curve. Liao et al [9,14,15] investigated the behavior of twist deformation of asymmetric aluminum tube workpieces in rotary drawing bending process and characterized the influence of constitutive model on twist deformation prediction using experimental and numerical methods. A control strategy was proposed realizing twist deformation for lightweight automotive structures and drew the conclusion of improving formability and avoiding defects during the bending process.…”

Section: Introductionmentioning

confidence: 99%

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Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Wang

Xue

Bayraktar

et al. 2019

Metals

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This paper focuses on the twist defects and the control strategy in the process of four-roll bending for aluminum alloy Z-section profiles with large cross-section. A 3D finite element model (3D-FEM) of roll bending process has been developed, on the premise of the curvature radius of the profile, the particularly pronounced twist defects characteristic of 7075-O aluminum alloy Z-section profiles were studied by FE method. The simulation results showed that the effective control of the twist defects of the profile could be realized by adjusting the side roller so that the exit guide roll was higher than the entrance one (the side rolls presented an asymmetric loading mode with respect to the main rolls) and increasing the radius of upper roll. Corresponding experimental tests were carried out to verify the accuracy of the numerical analysis. The experimental results indicated that control strategies based on finite element analysis (FEA) had a significant inhibitory function on twist defects in the actual roll bending process.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Wang

Xue

Bayraktar

et al. 2019

Metals

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“…They found that the springback angle is sensitive to the hardening model. Xue et al (2015) developed an FE model of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric aluminium alloy tube. They found that the interfacial frictions have significant effects on twist springback of the tube.…”

Section: Introductionmentioning

confidence: 99%

An analytic model for tube bending springback considering different parameter variations of Ti-alloy tubes

Zhan

Wang

Yang

et al. 2016

Journal of Materials Processing Technology

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Springback after unloading is an issue that directly reduces the accuracy of bent tubes, especially for Ti-alloy tubes which are of high strength and low Young's modulus. The Young's modulus, E; wall thickness, t; and neutral layer, De, of a tube vary during the bending process. These variations may influence the bending deformation of components, thus on springback. Considering these variations, an analytic elastic-plastic tube bending springback model was established in this study based on the static equilibrium condition. When these variations were considered individually or combined, the resulting springback angles were all larger and closer to the experimental results than the results when variations were not considered for a D6 mm × t0.6 mm Ti-3Al-2.5V Ti-alloy tube. The t variation contribution is the large stand decreases the prediction error by 41.2%-45.3%. De variation ranks second and decreases the error by 21.2%-25.3%. E variation is the least significant, decreasing the error by only 2.4%. Furthermore, the influence of the stable Young's modulus Ea on the springback is larger than the initial Young's modulus E0. Therefore, for the bending springback of tubes with a small difference between E0and Ea and under a normal bending radius, E variation effects can be neglected. While for tubes with large differences between E0 and Ea, and high springback prediction requirements, the E variation should be replaced by Ea. The influences of the initial tube sizes, material properties and bent tube sizes of the Ti-3Al-2.5V tube on springback were obtained using the newly developed model. An analytic model for tube bending springback considering different parameter variations of Ti-alloy tubes

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“…A number of analytical models based on the geometry and the material characteristics have been conducted using the analytical methods for springback predictions. The recent approaches to analytical solutions include the prediction of springback considering Young's modulus variation with a piecewise hardening function [23], friction modeling of high strength steels [24][25], semi-analytical modeling of springback [26], U-bending as a function of stress distribution in the thickness of sheet metal [27], springback prediction of an asymmetric thin-walled tube [28], and an analytical springback model for lightweight hexagonal close-packed sheet [29]. In general, most of the analytical models assume a simplified process and material properties due to the complexity of the problem.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Springback in the Air Bending Process Using a Kriging Metamodel

Khadra

El-Morsy

2016

Eng. Technol. Appl. Sci. Res.

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This paper addresses the use of the kriging‏ approach to predict the springback in the air bending process. The materials and the geometrical parameters, which significantly affect the springback, were considered as inputs, and the springback angle was considered as the response. A verified nonlinear finite element model was used to generate the training data required to create the kriging‏ metamodel. The training examples were selected based on computer-generated D-optimal designs. A comparison between the kriging approaches and the response surface methodology is conducted and discussed. The results showed that kriging accurately predicts the finite element springback results. Comparing the accuracy of kriging with a response surface methodology shows that kriging with a 2nd degree polynomial and exponential correlation function predicts the springback more accurately than the response surface methodology.

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Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tube

Cited by 37 publications

References 18 publications

Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

An analytic model for tube bending springback considering different parameter variations of Ti-alloy tubes

Prediction of Springback in the Air Bending Process Using a Kriging Metamodel

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