Granular media filler assisted push bending method of thin-walled tubes with small bending radius

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

doi:10.1016/j.ijmecsci.2021.106365

Cited by 36 publications

(8 citation statements)

References 45 publications

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“…Al-Qureshi [19] proposed a technology using elastomer as the exible mandrel to act as the internal pressure transfer medium, which was suitable for the traditional bending methods of small-diameter thin-wall tubes. For the push bending process, Song et al [20] put forward a new granular media ller assisted the push bending method, which was veri ed by the effect of granular system parameters on forming. In 3D free bending, Guo et al [21] placed different lling materials in tubes, and the results illustrated that the steel ball in multi-point contact with the tube wall also had an ideal inhibitory effect on section distortion.…”

Section: Introductionmentioning

confidence: 99%

A novelty mandrel supported thin-wall tube bending cross-section quality analysis: a diameter-adjustable multi-point contact mandrel

Wang²,

Zhang³

et al. 2023

Int J Adv Manuf Technol

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The mandrel plays a vital role in metal tube bending limit improvement and high-quality achievement. For the bending forming process of metal tubes with different diameters, the corresponding mandrel needs to be customized, which has the disadvantages of a long design cycle, high manufacturing cost, and low reuse rate. To tackle this issue, a novelty concept of diameter adjustable mandrel (DAM) based on the multi-point contact was put forward to adapt different diameters tubes bending processes. Since the point-contact characteristics of the DAM can lead to irregular cross-section deformation, the crosssectional full pro le radial error (FP-RE) model was proposed as a more comprehensive evaluation model to measure the deformation degree of the whole bending cross-section. A diameter-adjustable DAM was adopted in the AISI 304L tubes (the inner diameter = 40-56 mm) bending experiments. The maximum absolute error of FP-RE was 0.11% compared with the ones obtained from FEA in Abaqus/explicit. In addition, the effects of the DAM characteristic parameters, viz., the support blocks amount, the effective magni cation, and the effective support diameter, on the tube forming quality were discussed. The results indicated that: (a) An even number of support blocks could prevent the collapse of the outer convex tube wall and improve the quality of the inner concave tube wall. (b) When the DAM was used in the large inner diameter tubes bending, the larger non-contact area would cause an increase in the roundness section distortion. (c) For the tubes with the same diameter, a larger DAM diameter would lead to a smaller cross-section deformation degree, while the wall thinning was just the opposite. Finally, the result also proved that the DAM (the minimum effective diameter is 40 mm with six support blocks) could be used for tubes with an inner diameter of about 40-56 mm, and the forming quality was acceptable.

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Section: Introductionmentioning

confidence: 99%

A novelty mandrel supported thin-wall tube bending cross-section quality analysis: a diameter-adjustable multi-point contact mandrel

Wang²,

Zhang³

et al. 2023

Int J Adv Manuf Technol

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“…In order to rationalize the spatial structure of components, the structural design of tube parts is increasingly complicated, and its geometric structure is mostly characterized by an overall large expansion rate and local small features. At present, the forming technology of tube includes hydroforming [ 6 , 7 ], particle-assisted tube forming [ 8 ], magnetorheological elastomer forming [ 9 ], tubular channel angular pressing (TCAP) and parallel tubular-channel angular pressing (PTCAP) [ 10 , 11 ] and so on. However, due to the high deformation resistance and poor formability of aluminum alloy at room temperature, it is difficult to manufacture by hydroforming, which hinders further wide application [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Hot Metal Gas Forming Process on Formability and Microstructure of 6063 Aluminum Alloy Double Wave Tube

Wang

et al. 2023

Materials

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The hot metal gas forming process can significantly improve the formability of a tube and is suitable for the manufacturing of parts with complex shapes. In this paper, a double wave tube component is studied. The effects of different temperatures (400 °C, 425 °C, 450 °C and 475 °C) and different pressures (1 MPa, 1.5 MPa, 2 MPa, 2.5 MPa and 3 MPa) on the formability of 6063 aluminum alloy tubes were studied. The influence of hot metal gas forming process parameters on the microstructure was analyzed. The optimal hot metal gas forming process parameters of 6063 aluminum alloy tubes were explored. The results show that the expansion rate increases with the increase in pressure. The pressure affects the deformation of the tube, which in turn has an effect on the dynamic softening of the material. The expansion rate of parts also increases with the increase in forming temperature. The increased deformation temperature is beneficial to the dynamic recrystallization of 6063, resulting in softening of the material and enhanced deformation uniformity between grains, so that the formability of the material is improved. The optimum hot metal gas forming process parameters of 6063 aluminum alloy tubes are the temperature of 475 °C and the pressure of 2.5 MPa; the maximum expansion ratio is 41.6%.

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“…Metallic tube component is widely used in various industrial fields such as aviation, aerospace, nuclear energy engineering and automobile due to its lightweight, high-strength and low energy consumption [1]. The welded tube, as a typical metallic tube component, is becoming more widespread in multitudinous industries owing to the low cost, short production period and great variety [2].…”

Section: Introductionmentioning

confidence: 99%

Investigation on the influence of weld position on the deformation behavior of welded tube during free bending process

Cheng

Pan

Bai

et al. 2022

Int J Adv Manuf Technol

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The non-uniform distribution of the mechanical properties of welded tube would affect the plastic deformation behavior of tube during the free bending process. To explore the influence of weld position on the forming quality and axis dimensional accuracy of welded tube, the free bending experiment and numerical simulation of welded tube were conducted in this paper. First, the principle of free bending was theoretical deduced and the stress distribution of bent tube was analyzed. Then the hardness test and uniaxial tensile test were conducted to obtain the mechanical properties of weld zone and parent zone of welded tube. The material strength in the weld zone of welded tube is significantly higher than that in the parent zone.Finally, the free bending experiment and numerical simulation with different weld position were carried out, and the influence of weld position on the bending radius, cross-sectional distortion and wall thickness of bent tube was discussed. All these findings advance the insight into the free bending deformation behavior of welded tube and help to improve the forming quality of welded tube and facilitate the application of free bending technology in welded tube.

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Granular media filler assisted push bending method of thin-walled tubes with small bending radius

Cited by 36 publications

References 45 publications

A novelty mandrel supported thin-wall tube bending cross-section quality analysis: a diameter-adjustable multi-point contact mandrel

A novelty mandrel supported thin-wall tube bending cross-section quality analysis: a diameter-adjustable multi-point contact mandrel

Effect of Hot Metal Gas Forming Process on Formability and Microstructure of 6063 Aluminum Alloy Double Wave Tube

Investigation on the influence of weld position on the deformation behavior of welded tube during free bending process

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