journal article·2023-09

Effect of bending radius on deformation behavior of H62 brass tubes in a less constrained free bending process

Jiawei Jiang, Xunzhong Guo, Yizhou Shen, Yangjiangshan Xu, Zhen Wang, Huaguan Li, Jie Tao

Publisher page

Abstract

Finite element method and bending experiments were carried out to survey the influence of bending radius on forming quality of H62 brass tubes in free bending process,which are widely used as key components of pipeline system in aerospace, aviation and automotive fields. Different bending radiuses ranged from 45 mm to 100 mm with an interval of 5 mm were employed to survey the forming defects. The results illustrated that both cross-section distortion and wall thickness variations at sections with angles in range of 10–20° and 160–170° were larger than other regions. The severe deformation behaviors usually occurred at the end of the tubes. Moreover, similar to the variation tendency of cross-section distortion, the changing of wall thickness decreases gradually with the increase of bending radius. Furthermore, the positions with the severer forming defects gradually moved towards to two terminals of the tubes with increasing bending radius. The variations of these deformation behaviors were mainly caused by the tangential stress and axial stress which were decomposed by an extra thrust introduced by the bending die. Based on the above force analysis and experimental results, the credible analytical equations were derived to quantify the effect of bending radius on forming precision during the practical bending process.
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Metal Forming Simulation Techniques · Metallurgy and Material Forming · Aluminum Alloy Microstructure Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (50)

Show source-provided references
1. Xiao YH, Guo C, Guo XY (2011) Constitutive modeling of hot deformation behavior of H62 brass. Mater Sci Eng A 528(21):6510–651810.1016/j.msea.2011.04.090 ↗
2. Hashmi MSJ (2006) Aspects of tube and pipe manufacturing processes: meter to nanometer diameter. J Mater Process Technol 179(1–3):5–1010.1016/j.jmatprotec.2006.03.104 ↗
3. Guan Y, Pourboghrat F, Barlat F (2006) Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions. Int J Plasticity 22(12):2366–239310.1016/j.ijplas.2006.04.003 ↗
4. Ahmetoglu M, Altan T (2000) Tube hydroforming: state-of-the-art and future trends. J Mater Process Technol 98(1):25–3310.1016/S0924-0136(99)00302-7 ↗
5. Zhan M, Zhai H, He Y (2012) Springback mechanism and compensation of cryogenic Ti alloy tube after numerically controlled bending. T Nonferr Metal Soc 22:s287–s29310.1016/S1003-6326(12)61721-X ↗
6. Miller JE, Kyriakides S, Bastard AH (2001) On bend-stretch forming of aluminum extruded tubes - I: experiments. Int J Mech Sci 43(5):1283–131710.1016/S0020-7403(00)00039-4 ↗
7. Miller JE, Kyriakides S, Corona E (2001) On bend-stretch forming of aluminum extruded tubes—II: analysis. Int J Mech Sci 43(5):1319–133810.1016/S0020-7403(00)00040-0 ↗
8. Corona E (2004) A simple analysis for bend-stretch forming of aluminum extrusions. Int J Mech Sci 46(3):433–44810.1016/j.ijmecsci.2004.03.010 ↗
9. Xue X, Liao J, Vincze G, Gracio JJ (2015) Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tube. J Mater Process Technol 216:405–41710.1016/j.jmatprotec.2014.10.007 ↗
10. Shim DS, Kim KP, Lee KY (2016) Double-stage forming using critical pre-bending radius in roll bending of pipe with rectangular cross-section. J Mater Process Technol 236:189–20310.1016/j.jmatprotec.2016.04.033 ↗
11. Safari M, Farzin M (2014) A study on laser bending of tailor machined blanks with various irradiating schemes. J Mater Process Technol 214(1):112–12210.1016/j.jmatprotec.2013.08.007 ↗
12. Yilamu K, Hino R, Hamasaki H, Yoshida F (2010) Air bending and springback of stainless steel clad aluminum sheet. J Mater Process Technol 210(2):272–27810.1016/j.jmatprotec.2009.09.010 ↗
13. Li H, Yang H, Yan J, Zhan M (2009) Numerical study on deformation behaviors of thin-walled tube NC bending with large diameter and small bending radius. Comput Mater Sci 45(4):921–93410.1016/j.commatsci.2008.12.018 ↗
14. Li H, Yang H, Zhan M, Kou YL (2010) Deformation behaviors of thin-walled tube in rotary draw bending under push assistant loading conditions. J Mater Process Technol 210(1):143–15810.1016/j.jmatprotec.2009.07.024 ↗
15. He Y, Jing Y, Mei Z, Li H, Kou YL (2009) 3D numerical study on wrinkling characteristics in NC bending of aluminum alloy thin-walled tubes with large diameters under multi-die constraints. Comput Mater Sci 45(4):1052–106710.1016/j.commatsci.2009.01.010 ↗
16. Chen J, Daxin E, Zhang J (2013) Effects of process parameters on wrinkling of thin-walled circular tube under rotary draw bending. Int J Adv Manuf Tech 68(5–8):1505–151610.1007/s00170-013-4938-5 ↗
17. Al-Qureshi HA (1999) Elastic-plastic analysis of tube bending. Int J Mach Tool Manu 39(1):87–10410.1016/S0890-6955(98)00012-1 ↗
18. Kami A (2011) Prediction of wrinkling in thin-walled tube push-bending process using artificial neural network and finite element method. P I Mech Eng B-J Eng 225(10):1801–1812
19. Song HW, Xie W, Zhang SH, Jiang W, Lăzărescu L, Banabic D (2021) Granular media filler assisted push bending method of thin-walled tubes with small bending radius. Int J Mech Sci 198:10636510.1016/j.ijmecsci.2021.106365 ↗
20. Du B, Zhao CC, Dong GJ et al (2017) FEM-DEM coupling analysis for solid granule medium forming new technology. J Mater Process Technol 249:108–11710.1016/j.jmatprotec.2017.05.024 ↗
21. Chen H, Güner A, Khalifa NB, Tekkaya AE (2016) Granular media-based tube press hardening. J Mater Process Technol 228:145–15910.1016/j.jmatprotec.2015.03.028 ↗
22. Chen H, Hess S, Haeberle J, Pitikaris S, Born P, Güner A, Sperl M, Tekkaya AE (2016) Enhanced granular medium-based tube and hollow profile press hardening. CIRP Ann-Manuf Technol 65(1):273–27610.1016/j.cirp.2016.04.010 ↗
23. Dong GJ, Zhao CC, Peng YX, Li Y (2015) Hot granules medium pressure forming process of AA7075 conical parts. Chin J Mech Eng 28:580–59110.3901/CJME.2015.0217.019 ↗
24. Dong GJ, Bi J, Du B, Zhao CC (2017) Research on AA6061 tubular components prepared by combined technology of heat treatment and internal high pressure forming. J Mater Process Technol 242:126–13810.1016/j.jmatprotec.2016.11.035 ↗
25. Jianjun WU, Zhang Z (2021) An improved procedure for manufacture of 3D tubes with springback concerned in flexible bending process. Chin J Aeronaut 34(11):267–27610.1016/j.cja.2020.05.036 ↗
26. He Y, Heng L, Zhang Z, Mei ZHAN, Jing LIU, Guangjun L (2012) Advances and trends on tube bending forming technologies. Chin J Aeronaut 25(1):1–1210.1016/S1000-9361(11)60356-7 ↗
27. Ancellotti S, Fontanari V, Slaghenaufi S, Cortelletti E, Benedetti M (2019) Forming rectangular tubes into complicated 3D shapes by combining three-roll push bending, twisting and rotary draw bending: the role of the fabrication loading history on the mechanical response. Int J Mater Form 12:907–92610.1007/s12289-018-1453-0 ↗
28. Gantner P, Harrison DK, De Silva AKM, Bauer H (2004) New bending technologies for the automobile manufacturing industry. In: Proceedings of the 34th international MATADOR conference. Springer, London, pp 211–21610.1007/978-1-4471-0647-0_32 ↗
29. Li P, Wang L, Li M (2016) Flexible-bending of profiles with asymmetric cross-section and elimination of side bending defect. Int J Adv Manuf Tech 87(9–12):2853–228510.1007/s00170-016-8673-6 ↗
30. Li H, Yang H, Zhang ZY et al (2014) Multiple instability-constrained tube bending limits. J Mater Process Technol 214(2):445–45510.1016/j.jmatprotec.2013.09.027 ↗
31. Zhu YX, Liu YL, Yang H et al (2013) Improvement of the accuracy and the computational efficiency of the springback prediction model for the rotary-draw bending of rectangular H96 tube. Int J Mech Sci 66:224–23210.1016/j.ijmecsci.2012.11.012 ↗
32. Zhang Z, Wu J, Zhang S et al (2016) A new iterative method for springback control based on theory analysis and displacement adjustment. Int J Mech Sci 105:330–33910.1016/j.ijmecsci.2015.11.005 ↗
33. Murata M, Kuboki T (2015) CNC tube forming method for manufacturing flexibly and 3-dimensionally bent tubes [M]//60 excellent inventions in metal forming. Springer Vieweg, Berlin, Heidelberg, pp 363–368
34. Guo X, Ma Y, Chen W et al (2018) Simulation and experimental research of the free bending process of a spatial tube. J Mater Process Technol 255:137–14910.1016/j.jmatprotec.2017.11.062 ↗
35. Li P, Wang L, Li M (2017) Flexible-bending of profiles and tubes of continuous varying radii. Int J Adv Manuf Tech 88(5–8):1669–167510.1007/s00170-016-8885-9 ↗
36. Gantner P, Bauer H, Harrison DK et al (2005) Free-bending —a new bending technique in the hydroforming process chain. J Mater Process Technol 167(2–3):302–30810.1016/j.jmatprotec.2005.05.052 ↗
37. Shimada N, Tomizawa A, Kubota H et al (2014) Development of three-dimensional hot bending and direct quench technology. Procedia Eng 81:2267–227210.1016/j.proeng.2014.10.319 ↗
38. Chatti S, Hermes M, Tekkaya AE et al (2010) The new TSS bending process: 3D bending of profiles with arbitrary cross-sections. CIRP Ann 59(1):315–31810.1016/j.cirp.2010.03.017 ↗
39. Farina S, Gemignani R, Mentella A et al (2009) In: Tube free bending: a new index for the control of the cross section quality[C]//IX Convegno Associazione Italiana Tecnologia Meccanica AITEM. ITA,. p. 1–6
40. Liu K, Liu Y, Yang H (2013) Experimental study on the effect of dies on wall thickness distribution in NC bending of thin-walled rectangular 3A21 aluminum alloy tube. Int J Adv Manuf Tech 68(5–8):1867–187410.1007/s00170-013-4983-0 ↗
41. Goodarzi M, Kuboki T, Murata M (2005) Deformation analysis for the shear bending process of circular tubes. J Mater Process Technol 162:492–49710.1016/j.jmatprotec.2005.02.090 ↗
42. Goodarzi M, Kuboki T, Murata M (2007) Effect of initial thickness on shear bending process of circular tubes. J Mater Process Technol 191(1–3):136–14010.1016/j.jmatprotec.2007.03.007 ↗
43. Goodarzi M, Kuboki T, Murata M (2007) Effect of die corner radius on the formability and dimensional accuracy of tube shear bending. Int J Adv Manuf Tech 35(1–2):66–7410.1007/s00170-006-0697-x ↗
44. Jiang Z, Mei Z, Yang H, Xu X, Li G (2011) Deformation behavior of medium-strength TA18 high-pressure tubes during NC bending with different bending radii. Chin J Aeronaut 24(5):657–66410.1016/S1000-9361(11)60077-0 ↗
45. Liu KX, Zheng S, Zheng YS, Chen Y, He Y (2017) Plate assembly effect and cross-section distortion of rectangular tube in rotary draw bending. Int J Adv Manuf Tech 90(1–4):177–18810.1007/s00170-016-9283-z ↗
46. Liu K, Liu Y, Yang H (2014) Experimental and FE simulation study on cross-section distortion of rectangular tube under multi-die constraints in rotary draw bending process. Int J Prec Eng Manuf 15(4):633–64110.1007/s12541-014-0381-2 ↗
47. Xunzhong GUO, Xuan et al (2020) Finite element modelling and experimental investigation of the impact of filling different materials in copper tubes during 3D free bending process. Chin J Aeronaut 167(02):336–344
48. Wang X, Li F (2015) Analysis of wall thickness variation in the hydro-bending of a double-layered tube. Int J Adv Manuf Tech 81(1–4):67–7210.1007/s00170-015-7188-x ↗
49. E D X, Zhou D J. (2016) Metal tube bending: theory and forming defects analysis. Beijing Institute of Technology Press, Beijing
50. Tang NC (2000) Plastic-deformation analysis in tube bending. Int J Pre Ves Pip 77(12):751–75910.1016/S0308-0161(00)00061-2 ↗