A modified thin-walled tube push-bending process with polyurethane mandrel

Jiang, Weihao; Xie, Wenlong; Song, Hong-Wu; Lăzărescu, Lucian; Zhang, Shihong; Banabic, Dorel

doi:10.1007/s00170-019-04827-3

Cited by 18 publications

(11 citation statements)

References 25 publications

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“…According to the theory of elastic mechanics, the constitutive equation of the MREs specimen in the cylindrical coordinate system can be expressed as (Jiang et al, 2020):…”

Section: Resultsmentioning

confidence: 99%

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The study on the mechanical properties of magnetorheological elastomers under triaxial compression

et al. 2020

Journal of Intelligent Material Systems and Structures

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In order to design magnetorheological elastomers (MREs) based craftsmanship for metal forming, a comprehensive study on the mechanical properties of MREs under triaxial compression is required. An experimental setup integrating free compression and triaxial compression is designed to characterize isotropic MREs specimens under compression mode. The results showed that the MREs specimen in mold had successively experienced free compression stage, transition stage and triaxial compression stage during the experiment. The stress-strain curves of the MREs specimen changed when the concentration of magnetic particles increased from 0 to 44.7%, and the strain required to reach the transition stage was reduced. The effect of magnetic flux density on the stress-strain curves of the MREs specimen depended on the concentration of magnetic particles. The measured data obtained at different strain rates revealed maximum changes of 15.7% and 0.096% in volume compression modulus and Poisson ratio, respectively, which occurred under the magnetic flux density of 200 mT and CIP concentrations of [Formula: see text]. In this study, through a set of experiments, the stress-strain curves of the MREs specimen under different concentrations was elucidated, and their effects on the volume compression modulus and Poisson ratio were discussed.

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“…According to the theory of elastic mechanics, the constitutive equation of the MREs specimen in the cylindrical coordinate system can be expressed as (Jiang et al, 2020):…”

Section: Resultsmentioning

confidence: 99%

“…Therefore, the axial strain ε Z of the specimen is the volume strain θ. The ε Z in equation (1) can be expressed as (Jiang et al, 2020):…”

Section: Resultsmentioning

confidence: 99%

The study on the mechanical properties of magnetorheological elastomers under triaxial compression

et al. 2020

Journal of Intelligent Material Systems and Structures

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“…Fig. 1 Schematics of the tube push-bending process with polyurethane mandrel (a) before bending (b) after bending [19].…”

Section: Forming Processmentioning

confidence: 99%

Process Parameters Optimization for Thin-walled Tube Push-bending Using Response Surface Methodology

Xie

Jiang

et al. 2021

Preprint

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In this paper, the response surface methodology (RSM) and finite element (FE) simulation were applied to optimize the push-bending process parameters of the thin-walled tube with polyurethane mandrel. The objective of the present work is to predict the optimal set of process parameters including the relative length of the mandrel (L/D), the friction coefficient between die and tube (μ1), the friction coefficient between polyurethane and tube (μ2) and Poisson’s ratio of polyurethane (υ) to obtain qualified bent tubes. Three empirical models were developed to describe the relationship between process parameters and quality parameters of the bent tubes. In addition, the significant factors affecting the forming quality were analyzed using analysis of variance (ANOVA) of each model. Response surfaces were constructed to study the effect of each process parameter on the quality of the bent tubes. Finally, the process optimization window with the maximum thinning rate (ϑ) less than 20%, the maximum thickening rate (ψ) less than 17%, and the maximum cross-section ovality (ξ) less than 5% of the bent tube was established. Qualified bent tubes with diameter of 144 mm, wall thickness of 2 mm, and bending radius of 280 mm were formed experimentally by following the established process window.

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“…Liu and Song et al [11,12] presented a new push-bending method with granular media filler for thin-walled tubes with a small relative bending radius, and developed a 3D FEM-DEM coupling numerical model to prove the advantages of granular media in preventing tube forming defects, especially wrinkling. Xu and Jiang et al [13,14] proposed a novel push-bending method using a polyurethane mandrel. The influence of diameter, thickness, total length, and the arrangement of cylindrical polyurethane rubber filler on the push-bending deformation of the tube was explored by means of simulations and experiments.…”

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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A modified thin-walled tube push-bending process with polyurethane mandrel

Cited by 18 publications

References 25 publications

The study on the mechanical properties of magnetorheological elastomers under triaxial compression

The study on the mechanical properties of magnetorheological elastomers under triaxial compression

Process Parameters Optimization for Thin-walled Tube Push-bending Using Response Surface Methodology

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

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