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Role of the mandrel in the variable curvature local-induction-heating bending process of B1500HS thin-walled rectangular tubes

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Abstract

The variable curvature local-induction-heating bending forming (VC-LIHBF) technology is commonly used in the automotive industry to lighten and stiffen the structure parts. This technology allows the simultaneously bending forming and hardening of ultrahigh strength steel tubes, and allows the tensile strength of B1500HS steel to reach 1500 MPa. By adjusting the bending curvature parameters of the experimental facility through the numerical control system, the production of the tubes with variable curvatures could be achieved without changing dies. However, the more major problem of wrinkling occurs when a small-radius bending is applied on thin-walled rectangular tubes. This paper focuses on improving of forming quality and forming limit of the thin-walled rectangular steel tube (TWRST) with mandrel supported. In this study, an analytical model of the mandrel is established and some reference formulas for the selection of the mandrel parameters are deduced. Based on the above analysis, a three-dimensional elastic-plastic finite element method (FEM) model of the LIHBF process of the B1500HS TWRST is developed using the dynamic explicit FEM code ABAQUS/Temp-disp/Explicit, and key technological problems are solved. Experiments are carried out to verify the accuracy of the analytical model and confirm the reliability of the FEM model. The influences of the mandrel on stress distribution during the local-induction-heating bending process are also investigated. The influence mechanism of the mandrel parameters on the minimum radius of the LIHBF without wrinkling and the forming quality is revealed. The appropriate process parameters for the B1500HS TWRST are obtained through experiments and simulations.

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Funding

The work was supported by Project of Laboratory of Lightweight Structure & Advanced Forming Technology, Harbin Institute of Technology, P. R China (No. MH20170272 and No. MH20190289).

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Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Tingjun Cai, Chengxi Lei, Wenyu Yang, Hongya Fu & Zhongwen Xing

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  1. Tingjun Cai
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  2. Chengxi Lei
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  3. Wenyu Yang
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  4. Hongya Fu
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  5. Zhongwen Xing
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Contributions

Cai TJ, Lei CX, and Fu HY conceived and designed the study; Cai TJ performed the experiments and provided figures and tables; Cai TJ, Lei CX, and Yang WY analyzed the data and edited the manuscript. Lei CX, Yang WY, Fu HY, and Xing ZW reviewed and improved the manuscript.

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Correspondence to Chengxi Lei.

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Cai, T., Lei, C., Yang, W. et al. Role of the mandrel in the variable curvature local-induction-heating bending process of B1500HS thin-walled rectangular tubes. Int J Adv Manuf Technol 114, 625–640 (2021). https://doi.org/10.1007/s00170-021-06614-5

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