Role of filling material on defects of thin-walled tube bending process

• Autorzy: Sedighi M. , Kahnamouei J. T.
• Języki publikacji: EN

Abstrakty

EN

This paper investigates approaches to avoid common defects such as the wrinkling, cross section distortion and changing in wall thickness in the bending process of a thin-walled tube. A series of experimental tests has been carried out by filling the tube with melted lead and different types of rubbers. Firstly, tubes were filled by several kinds of rubbers and bended, but the wrinkling was observed at the inner side of the tubes. Also the cross section distortions happened to be above the acceptable range. Therefore, rubbers could not be a suitable filling material for steel tubes. As the second case, lead was used as the filling material to avoid the defects. For this purpose, the tubes were filled by liquid lead and it was solidified to form a leady core to support the inner part of the tube bend. After the bending process, lead is melted and removed. This removable leady core was called the ‘Leady Lost Core’. To study the process numerically, a 3D finite element model of the horizontal bending process has been built using a commercial code. Experimental tests have been carried out to verify the simulation results and developed to provide additional insight. To consider the friction coefficient, in this work, “The Barrel Compression Test” method has been used. Comparisons between the experimental and finite element results have shown remarkable agreement. They show that wrinkle initiation and cross section distortion can be avoided with a lost core of low temperature melting metal like lead or tin.

Słowa kluczowe

EN

thin-walled tube; bending process; low temperature melting metal

• Wydawca: Polskie Towarzystwo Mechaniki Teoretycznej i Stosowanej
• Czasopismo: Journal of Theoretical and Applied Mechanics
• Rocznik: 2014
• Tom: Vol. 52 nr 1
• Strony: 227--233
• Opis fizyczny: Bibliogr. 16 poz., rys., tab.

Twórcy

autor

Sedighi M.

• School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran

autor

Kahnamouei J. T.

• Islamic Azad University, Bostan Abad Branch, Mechanical Engineering Department, Iran

Bibliografia

• 1. Baudin S., Ray P., Donald B.J.M., Hashmi. M.S.J., 2004, Development of a novel method of tube bending using finite element simulation, Journal of Materials Processing Technology, 153/154, 128-133
• 2. Ebrahimi R., Najafizadeh A., 2004, A new method for evaluation of friction in bulk metal forming, Journal of Materials Processing Technology, 152, 136-143
• 3. Guarracino F., 2003, On the analysis of cylindrical tubes under flexure: theoretical formulations, experimental data and finite element analyses, Thin-Walled Structures, 41, 127-147
• 4. Hwang Y.M., Tzou G.Y., 1997, Analytical and experimental study on asymmetric sheet rolling, International Journal of Mechanical Sciences, 39, 289-303
• 5. Jiang Z., Zhan M., Yang H., Xu X., Li G., 2011, Deformation behavior of medium-strength TA18 high-pressure tubes during NC bending with different bending radii, Chinese Journal of Aeronautics, 24, 5, 657-664
• 6. Koc M., Altan T., 2001, An overall review of the tube hydroforming (THF) technology, Journal of Materials Processing Technology, 108, 384-393
• 7. Lee H., Van Tyne C.J., Field D., 2005, Finite element bending analysis of oval tubes using rotary draw bender for hydroforming applications, Journal of Materials Processing Technology, 168, 327-335
• 8. Li H., Yang H., Zhan M., Gu R.J., 2006, A new method to accurately obtain wrinkling limit diagram in NC bending process of thin-walled tube with large diameter under different loading paths, Journal of Materials Processing Technology, 177, 192-196
• 9. Manabe K., Amino M., 2002, Effects of process parameters and material properties on deformation process in tube hydroforming, Journal of Materials Processing Technology, 123, 285-291
• 10. Ohashi T., Matsui K., Saotome Y., 2001, The lateral extrusion of copper pipe with a lost core of low temperature melting alloy, Journal of Materials Processing Technology, 113, 98-102
• 11. Tian S., Liu Y., Yang H., 2013, Effects of geometrical parameters on wrinkling of thin-walled rectangular aluminum alloy wave-guide tubes in rotary-draw bending, Chinese Journal of Aeronautics, 26, 1, 242-248
• 12. Tang N.C., 2000, Plastic-deformation analysis in tube bending, International Journal of Pressure Vessels and Piping, 77, 751-759
• 13. Wang Y., Han C., Yuan S., 2012, Effect of internal pressure on corner radius and thickness distribution of shear hydro-bending of 5A02 aluminum alloy tube, Transactions of Nonferrous Metals Society of China, 22, 2, 376-381
• 14. Yang H., Gu R.-J., Zhan M., Li H., 2006, Effect of frictions on cross section quality of thinwalled tube NC bending, Transactions of Nonferrous Metals Society of China, 16, 4, 878-886
• 15. Yang H., Lin Y., 2004, Wrinkling analysis for forming limit of tube bending processes, Journal of Materials Processing Technology, 152, 363-369
• 16. Zhang Z., Yang H., Li H., Ren N., Tian Y., 2011, Bending behaviors of large diameter thinwalled CP-Ti tube in rotary draw bending, Progress in Natural Science: Materials International, 21, 401-412