A new mandrel design with mandrel ball thickness variation for the bending process of aviation ultra-thin-walled tubes

Jiang, Lijian; Lin, Yaochen; Li, Heng; Zhang, Shuyou; Feng, Ying; Wang, Yaqun; Sun, Min

doi:10.1007/s00170-022-09954-y

Cited by 3 publications

(1 citation statement)

References 21 publications

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“…Wrinkling is the main form of instability in the tube forming process, and includes bending, compression or liquid expansion. This wrinkling instability generally tends to be localized, and can possibly lead to catastrophic failure such as collapse or rupture [ 126 , 127 ]; wrinkling can also destabilize the tube surface, resulting in thinner or thicker walls [ 128 , 129 , 130 , 131 ].…”

Section: Deformation Instability Induced By the Structural Geometry O...mentioning

confidence: 99%

Theory, Method and Practice of Metal Deformation Instability: A Review

Wan

Yao

et al. 2023

Materials

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Deformation instability is a macroscopic and microscopic phenomenon of non-uniformity and unstable deformation of materials under stress loading conditions, and it is affected by the intrinsic characteristics of materials, the structural geometry of materials, stress state and environmental conditions. Whether deformation instability is positive and constructive or negative and destructive, it objectively affects daily life at all times and the deformation instability based on metal-bearing analysis in engineering design has always been the focus of attention. Currently, the literature on deformation instability in review papers mainly focuses on the theoretical analysis of deformation instability (instability criteria). However, there are a limited number of papers that comprehensively classify and review the subject from the perspectives of material characteristic response, geometric structure response, analysis method and engineering application. Therefore, this paper aims to provide a comprehensive review of the existing literature on metal deformation instability, covering its fundamental principles, analytical methods, and engineering practices. The phenomenon and definition of deformation instability, the principle and viewpoint of deformation instability, the theoretical analysis, experimental research and simulation calculation of deformation instability, and the engineering application and prospect of deformation instability are described. This will provide a reference for metal bearing analysis and deformation instability design according to material deformation instability, structural deformation instability and localization conditions of deformation instability, etc. From the perspective of practical engineering applications, regarding the key problems in researching deformation instability, using reverse thinking to deduce and analyze the characteristics of deformation instability is the main trend of future research.

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Section: Deformation Instability Induced By the Structural Geometry O...mentioning

confidence: 99%

Theory, Method and Practice of Metal Deformation Instability: A Review

Wan

Yao

et al. 2023

Materials

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High precision ultrasonic measurement method for thin-walled parts

Chen,

Ji,

Zhang

et al. 2024

NDT & E International

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Effects of Asymmetric Thickness Mandrel on NC RDB Forming Quality of Ultra-Thin-Walled Tube

Jang,

Yuan,

et al. 2024

Preprint

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To satisfy lightweight design requirements, aerospace ducts frequently employ ultra-thin-walled tubes with a diameter-to-thickness ratio (D/t) exceeding 100.However, ultra-thin-walled tubes present significant forming challenges, and the mandrel plays a critical role in their bending. Therefore, investigating the effect of mandrel structure on the quality of ultra-thin-walled tubes formed through NC bending is of considerable importance. In this study, utilizing the Abaqus nonlinear finite element platform, an asymmetric thickness ball design method is proposed. Based on the positioning of the asymmetric balls within the mandrel, seven distinct designs for asymmetric thickness mandrels are developed. This study conducts a finite element analysis of the NC rotary draw bending (RDB) process for ultra-thin-walled 304 stainless steel tubes and validates the corresponding experiments. The results indicate that as the asymmetric thickness mandrel is positioned further from the mandrel, the stress on the outer side of the tube near the bend initiation first increases and then decreases, while the stress on the inner side of the tube, after the midpoint of the bend, initially decreases and then increases. The use of asymmetric thickness mandrels significantly reduces both the thinning and thickening rates of the tubes, though their impact on improving the ellipticity is less pronounced. The core ball nearest to the mandrel is designated as Ball 1, with subsequent balls further from the mandrel labeled as Ball 2 and Ball 3, respectively. The placement of the asymmetric thickness balls improves the thinning rate in the order: Ball 2 > Ball 1 > Ball 3; enhances the thickening rate in the order: Ball 1 > Ball 2 > Ball 3; and optimizes the ellipticity in the order: Ball 3 > Ball 1 > Ball 2.

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A new mandrel design with mandrel ball thickness variation for the bending process of aviation ultra-thin-walled tubes

Cited by 3 publications

References 21 publications

Theory, Method and Practice of Metal Deformation Instability: A Review

Theory, Method and Practice of Metal Deformation Instability: A Review

High precision ultrasonic measurement method for thin-walled parts

Effects of Asymmetric Thickness Mandrel on NC RDB Forming Quality of Ultra-Thin-Walled Tube

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