Abstract
The clearances between tube and various dies have a significant and complicated influence on the onset of wrinkling during the rotary draw bending process. To study the effect of clearance on wrinkling, a 3D finite element (FE) model of the process for thin-walled rectangular aluminum alloy tube has been built using the explicit code ABAQUS/Explicit and validated by comparing the experiment. Then, simulation and analysis of the process have been carried out based on the model. The influence laws of clearances between tube and various dies on wrinkling have been studied and the reasonable combination of clearances obtained using the combination method of 3D FE simulation and orthogonal experimental design. The results show that with the increase of tube mandrel clearance, Δc m, and tube bending die clearance, Δc b, the wrinkling wave number decreases rapidly, whereas the wrinkling wave height increases sharply. The effects of tube wiper die clearance, Δc w, and tube pressure die clearance, Δc p, on wrinkling are not significant. The reasonable combination of clearances is Δc m = 0.15 mm, Δc b = 0 mm, Δc w = 0 mm, and Δc p = 0 mm. These achievements are helpful to the design and optimization of the process.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Vollertsen F, Sprenger A, Kraus J, Arnet H (1999) Extrusion, channel, and profile bending: a review. J Mater Process Technol 87:1–27
Stange RR (1997) Tooling and methods for tube and pipe bending: the importance of proper equipment and proven techniques. Tube Pipe J 8(8):28–35
Strano M (2005) Automatic tooling design for rotary draw bending of tubes. Int J Adv Manuf Technol 26:733–740
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 Technol 35:66–74
Paulsen F, Welo T (2001) Cross-sectional deformations of rectangular hollow sections in bending: part I—experiments. Int J Mech Sci 43(1):109–129
Paulsen F, Welo T (2001) Cross-sectional deformations of rectangular hollow sections in bending: part II—analytical models. Int J Mech Sci 43(1):131–152
Paulsen F, Welo T (2002) A design method for prediction of dimensions of rectangular hollow sections formed in stretch bending. J Mater Process Technol 128:48–66
Miller JE, Kyriakides S, Bastard AH (2001) On bend-stretch forming of aluminum extruded tubes I: experiments. Int J Mech Sci 43(5):1283–1317
Utsum N, Sakaki S (2002) Countermeasures against undesirable phenomena in the draw-bending process for extruded square tubes. J Mater Process Technol 123(264):269
Okude Y, Sakaki S, Yoshihara S (2008) Improving working limit in draw bending process of aluminum square tubes in large bending radius. Advanced Technol Plasticity 2008:564–569
Zhao GY (2007) Numerical simulation of wrinkling for rotary-draw bending process of thin-walled rectangular tube. MS thesis, Northwestern Polytechnical University, **’an, R. P. China (in Chinese)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhao, G., Liu, Y. & Yang, H. Effect of clearance on wrinkling of thin-walled rectangular tube in rotary draw bending process. Int J Adv Manuf Technol 50, 85–92 (2010). https://doi.org/10.1007/s00170-009-2508-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-009-2508-7