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Mandrel-Free Bending of Tubes with Small Radii – A Theoretical and Experimental Study

Michalczyk Jacek, Gontarz Andrzej, Wiewiórska Sylwia, Winiarski Grzegorz

Advances in Science and Technology. Research Journal

2023

Vol. 17, no 4

189--205

This paper presents the theoretical and experimental results of a study investigating a new method for tube bending. The method involves three-point bending of a tube without using a mandrel. The bending process was conducted with a small bending radius of Rg = 1.5Dz (where Dz is the outside diameter of the bent tube) and a large bending angle of 1800. The novelty of the proposed solution is the use of new shapes of bending roll impression. Instead of the standard circular-shaped impression, an elliptical-shaped impression was used. The aim of the study on the proposed small radius tube bending technique was to optimize the shape of roll impression in terms of minimizing ovalization and flattening of the tube cross section in the bending zone. Previous studies only showed that circular impressions were inefficient. The tube bending process conducted with a circular impression roll, without the use of a mandrel or other type of filling to achieve an angle ranging 900 ÷ 1800 , led to the flattening of the cross section. The tube wall in the upper zone would crack or its cross section would become deformed and oval. This theoretical and experimental study was conducted on tubes with an outside diameter of Dz=20 mm and a wall thickness of g=2 mm, made of 16Mo3 boiler steel and EN-AW 6060 aluminum alloy. Obtained results were then used to determine the ranges of bending roll impression parameters that ensured that the product would meet the standardized conditions of cross-sectional ovalization in the bending zone. The tool developed for this study can be applied in industrial practice.

Analiza technologii przelotowego nagrzewania walcówki do zakresu temperatur dwuetapowej obróbki cieplnej typu TRIP

Wiewiórska Sylwia, Muskalski Zbigniew, Wieczorek Paweł

Hutnik, Wiadomości Hutnicze

2019

Vol. 86, nr 12

370--377

W pracy przeanalizowano możliwość zastosowania szybkiego, oporowego lub indukcyjnego nagrzewania, półwyrobów długich (walcówki i drutów) do temperatury austenityzowania podczas dwuetapowej obróbki cieplnej, mającej zapewnić w materiale strukturę typu TRIP. Wykazano, że taki sposób nagrzewania wsadu do określonego przedziału temperatur z zakresu wyżarzania dwufazowego austenityczno-ferrytycznego zapewni odpowiednią ilość austenitu szczątkowego w strukturze materiału oraz równomierny rozkład własności mechanicznych na jego przekroju. Pozwoli to na skrócenie długości projektowanej linii technologicznej do obróbki cieplnej typu TRIP o ponad 50%.

The work explores the possibility of using fast, resistance or induction heating, long blanks (wire rods and wires) up to the austenitizing temperature during two-stage heat treatment to provide TRIP type structure in the material. It has been shown that this method of heating the feedstock to a specific temperature range in the two-phase austenitic-ferritic annealing range will ensure the right amount of retained austenite in the material structure and uniform distribution of mechanical properties on its cross-section. This will shorten the length of the designed TRIP type heat treatment technological line by over 50%.