Simulation and experimental research of the free bending process of a spatial tube

Guo, Xunzhong; Yan, Ma; Chen, Wenliang; Xiong, Hao; Xu, Yong; El-Aty, Ali Abd; Jin, Kai

doi:10.1016/j.jmatprotec.2017.11.062

Cited by 50 publications

(12 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The benefits of the process and its applications have been clearly demonstrated. In the same context, simulation and experimental analysis of the tube free bending have been introduced by Guo et al [4]. The distribution of the equivalent plastic strain (ϵ p ) on both the tube and the bending die has been analyzed throughout the different stages of bending.…”

Section: Introductionmentioning

confidence: 99%

Optimization of AL6061-T6 Tube End Forming Process Using Response Surface Method

Shaaban

Elsabbagh

2021

Modelling and Simulation in Engineering

View full text Add to dashboard Cite

Tube end closing is a metal forming process that replaces welding processes while closing tubes ends. It depends on deforming a rotating tube using a roller, and therefore, it is also called tube end spinning. The process involves many parameters like contact depth, roller inclination angle, roller diameter, mandrel curvature, and tube rotational speed. This study develops a finite element model (FE-model) for this process and validates it through experimental results. The numerical and experimental results have shown minor deviation of 1.87%. The FE-model is then employed to carry out a statistical analysis based on the response surface method (RSM). The analysis of variance (ANOVA) and regression analysis have proved the accuracy of the obtained mathematical model. The contact depth has proved to have the most significant effect in the process responses, while the roller diameter has the least effect. Finally, an optimization analysis is carried out to select the finest conditions for the process.

show abstract

Section: Introductionmentioning

confidence: 99%

Optimization of AL6061-T6 Tube End Forming Process Using Response Surface Method

Shaaban

Elsabbagh

2021

Modelling and Simulation in Engineering

View full text Add to dashboard Cite

show abstract

“…If torque is added to the clamp, a spatial tubular product can be formed easily. In current literature, Guo et al [10,11] established several mathematical models for determining the bending die positions during free bending and investigated the strain stress distributions along bending lines numerically. Plettke et al [12][13][14] investigated the relationship between mobile tool position and forming curvatures for push bending numerically and established the curvature distribution along bending lines when manufacturing arc-shaped products.…”

Section: Introductionmentioning

confidence: 99%

Trajectory Prediction of Three Dimensional Forming Tube Based On Kalman Filter

Yang

2021

Preprint

View full text Add to dashboard Cite

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.

show abstract

“…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

Self Cite

View full text Add to dashboard Cite

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.

show abstract

Simulation and experimental research of the free bending process of a spatial tube

Cited by 50 publications

References 23 publications

Optimization of AL6061-T6 Tube End Forming Process Using Response Surface Method

Optimization of AL6061-T6 Tube End Forming Process Using Response Surface Method

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

Contact Info

Product

Resources

About