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cross-section distortion and springback characteristics of double-cavity aluminum profile in force controlled stretch-bending

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Transactions of Nonferrous Metals Society of China 2024年第8期34卷 2476-2490页

作者： Zhi-wen LIU Zi-xuan DONG Cong-chang XU Jie YI Luo-xing LI School of Mechanical Engineering University of South ChinaHengyang 421001China State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle Hunan UniversityChangsha 410082China

3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent *** the computational accuracy and efficiency,the optimal choices of numerical parameters and algorithms in FE modelling were *** formation mechanisms of cross-section distortion and springback were *** effects of pre-stretching,post-stretching,friction,and the addition of internal fillers on forming quality were *** results show that the stress state of profile in stretch-bending is uniaxial with only a circumferential *** stress distribution along the length direction of profile is non-uniform and the maximum tensile stress is located at a certain distance away from the center of *** aluminum profile is gradually attached to bending die,the distribution characteristic of cross-section distortion along the length direction of profile changes from V-shape to *** unloading the forming tools,cross-section distortion decreases obviously due to the stress relaxation,with a maximum distortion difference of 13%before and after *** pre-stretching and post-stretching forces increase,cross-section distortion increases gradually,while springback first decreases and then remains *** increasing friction between bending die and profile,cross-section distortion slightly decreases,while springback ***-section distortion decreases by 83%with adding PVC fillers into the cavities of profile,while springback increases by 192.2%.

关键词： hollow aluminum profile force controlled stretch-bending numerical parameters springback analysis approach cross-section distortion springback process parameters

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Influence of mandrel-cores filling on size effect of cross-section distortion of bimetallic thin-walled composite bending tube

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Chinese Journal of Aeronautics 2023年第3期36卷 421-435页

作者： Yingxia ZHU Miaomiao WAN Wei CHEN Yun WANG Wenbin TU Fan XU School of Mechanical Engineering Jiangsu UniversityZhenjiang 212013China School of Mechanical Engineering Guilin University of Aerospace TechnologyGuilin 541004China

Two new size factors of cross-section hollow coefficient and bending degree are introduced to reveal the size effect of bending forming of bimetallic composite *** coefficient and bending degree can limit the commonly used bent tube to the size description range of(0,2.00).The evolution laws of the cross-section distortion forms in the hollow coefficient-bending degree interval are revealed as well as the action of the mandrel-cores on the size *** show the mandrel-cores filling can expand the forming limit of the bent tube,but also bring two other forming defects of wrinkle and *** identification factor(hollow coefficient multiply bending degree)provides a method for querying the cross-section distortion forms of all composite bending *** the identification factor interval(0,1.00),the distribution area of bending forming defects of the composite tube is *** thin-walled composite bending tube collapses when identification factor in(0,0.39),wrinkles when identification factor in[0.39,0.50),and ruptures when identification factor in[0.50,1.00).The mathematical model of size effect is derived,by which the average cross-section distortion rate is found to distribute like a radial leaf in the hollow coefficient-bending degree qualified forming *** best forming zone is hollow coefficient 0.46-0.68,and bending degree 0.25-0.47.

关键词： Bending Bimetallic composite tube cross-section distortion Size factor Size effect Mandrel

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Impact of bending dies with different friction forms on forming force and quality of tubes manufactured by free bending technology

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Chinese Journal of Aeronautics 2021年第4期34卷 253-264页

作者： Hao CHEN Hui WANG Ali ABD EL-ATY Yao QIN Jiang LI Yong ZHANG Tao LI Xunzhong GUO College of Material Science and Technology Nanjing University of Aeronautics and AstronauticsNanjing 211100China College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China Jiangsu Key Laboratory of Nuclear Energy Equipment Materials Engineering Nanjing University of Aeronautics and AstronauticsNanjing 211100China Mechanical Engineering Department Faculty of Engineering-HelwanHelwan UniversityCairoEgypt Nanjing Golden Dragon Bus Co. LtdNanjing 210012China

In the 3 D free bending forming system,the bending die can be designed either in a sliding type or rolling friction *** die-based sliding friction type is often called normal bending dies;however,the bending dies-based rolling friction type includes bending die-based roller type and ball type in *** the current study,the impact of three bending dies on the forming force,and the bent tube quality was *** obtained results showed that the tangential stresses and strains of the tubes formed by the bending die-based roller type were the smallest among the three bending ***,the spherical bearing force PUwas reduced drastically after using the roller type and ball type compared to the sliding friction ***,the uniformity of the wall thickness distribution of the tubes formed by the roller type and ball type was better than those obtained from the sliding friction *** addition,the cross-section distortion rate was reduced by 2.8%using the roller type,and 1.8%using ball-type compared to the sliding friction type.

关键词： Bending die cross-section distortion Rolling friction Sliding friction Spherical bearing force Wall thickness

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