Abstract
In free bending process, the axis shape of bent tube is determined by motion trajectory of bending die. The bent tubes with different bending radii and bending directions can be formed by continuously adjusting the position and posture of die. To accurately form the pre-designed bent tube, the formation mechanism of bending arc in free bending process was analyzed. The mathematical model between bending radius and deviation was established and the moving direction of bending die was also determined according to the plane space azimuth where the bending arc segment is located. The formation process of transition segments with variable curvature and variable bending direction is illustrated during the movement of bending die, and the influence of transition segment on the axis shape was also explored. By comparing the axis deviation of experimental and simulated bent tubes, the length of transition segment and the moving path of bending die can be optimized. Finally, the applicability of free bending forming technology in forming bent tubes with different axis features was verified by conducting free bending experiments on bent tubes with three typical shapes. Due to the high flexibility of free bending forming technology, the work in this paper could promote the engineering application of this technology in the precise control of axis shape of bent tube.
Similar content being viewed by others
Data availability
Not applicable.
Code availability
Not applicable.
References
Sun B, Qiu MX, Tian J, Shi F (2015) Research on design and process of external titanium alloy tube for aeroengine. Technol Innov 23–24:124–128
Han ZR, Liang WX, Liu BM, Li GJ (2015) Research on the examination technology for aircraft tube manufacturability. Mach Design Manuf 7:261–267. https://doi.org/10.19356/j.cnki.1001-3997.2015.07.072
Song HW, Xie WL, Zhang SH, Jiang WH, Lăzărescu L, Banabic D (2021) Granular media filler assisted push bending method of thin-walled tubes with small bending radius. Int J Mech Sci 198:106365. https://doi.org/10.1016/j.ijmecsci.2021.106365
Simonetto E, Ghiotti A, Bruschi S (2017) Dynamic detection of tubes wrinkling in three roll push bending. Procedia Eng 207:2316–2321. https://doi.org/10.1016/j.proeng.2017.10.1001
Fu MY, Wang ZL, Zhang SY, Liu XJ, Lin YC, Wang L (2022) Full-cross-section deformation characterization of Cu/Al bimetallic tubes under Rotary-Draw-Bending based on physics-driven B-spline curves fitting. Mater Des 215:110493. https://doi.org/10.1016/j.matdes.2022.110493
Welo T, Ma J, Blindheim J, Ha T, Ringen G (2020) Flexible 3D stretch bending of aluminium alloy profiles: an experimental and numerical study. Procedia Manuf 50:37–44. https://doi.org/10.1016/j.promfg.2020.08.008
Li T, Wang H, Abd El-Aty AA, Li J, Zhang Y, Wei WB, Chen H, Cheng X, Tao J, Guo XZ (2020) Theoretical modelling and finite element simulation of AA6061 involute components based on 3D free bending process. Int J Mech Sci 178:105607. https://doi.org/10.1016/j.ijmecsci.2020.105607
Gantner P, Bauer H, Harrison DK, De Silva AKM (2005) Free-bending—a new bending technique in the hydroforming process chain. J Mater Process Technol 167:302–308. https://doi.org/10.1016/j.jmatprotec.2005.05.052
Kleiner M, Tekkaya AE, Chatti S, Hermes M, Weinrich A, Ben-Khalifa N, Dirksen U (2009) New incremental methods for springback compensation by stress superposition. Prod Eng Res Devel 3:137–144. https://doi.org/10.1007/s12289-009-0613-7
Vatter PH, Plettke R (2013) Process model for the design of bent 3-dimensional free-form geometries for the three-roll-push-bending process. Procedia CIRP 7:240–245. https://doi.org/10.1016/j.procir.2013.05.041
Guo XZ, Xiong H, Xu Y, El-Aty AA, Ma YN, Zhao YH, Zhang SH (2018) U-R relationship prediction method for aluminum alloy circular tube free-bending process based on sensitivity analysis of material parameters. Int J Adv Manuf Technol 99:1967–1977. https://doi.org/10.1007/s00170-018-2614-5
Wei WB, Wang H, Xiong H, Cheng X, Tao J, Guo XZ (2020) Research on influencing factors and laws of free-bending forming limit of tube. Int J Adv Manuf Technol 106:1421–1430. https://doi.org/10.1007/s00170-019-04692-0
Beulich N, Craighero P, Volk W (2017) FEA Simulation of free-bending – a preforming step in the hydroforming process chain. J Phys: Conf Ser 896:012063. https://doi.org/10.1088/1742-6596/896/1/012063
Gantner P (2008) The characterisation of the free-bending technique. Dissertation, Glasgow Caledonian University
Staupendahl D, Tekkaya AE (2017) The reciprocal effects of bending and torsion on springback during 3D bending of profiles. Procedia Eng 207:2322–2327. https://doi.org/10.1016/j.proeng.2017.10.1002
Wu JJ, Zhang ZK, Shang Q, Li FF, Wang YA, Hui Y, Fan H (2017) A method for investigating the springback behavior of 3D tubes. Int J Mech Sci 131–132:191–204. https://doi.org/10.1016/j.ijmecsci.2017.06.047
Plettke R, Vatter P, Vipavc D (2012) Basics of process design for 3D freeform bending. Steel Res Int 307–310
Guo XZ, Ma YN, Chen WL, Xiong H, Xu Y, El-Aty AA, Jin K (2018) Simulation and experimental research of the free bending process of a spatial tube. J Mater Process Technol 255:137–149. https://doi.org/10.1016/j.jmatprotec.2017.11.062
Engel B, Kersten S, Anders D (2011) Spline-Interpolation and Calculation of Machine Parameters for the Three-Roll-Pushbending of Spline-Contours. Steel Res Int 82:1180–1186. https://doi.org/10.1002/srin.201100077
Groth S, Engel B, Frohn P (2018) Approach to a manufacture-oriented modeling of bent tubes depending on the curvature distribution during three-roll-push-bending. Proceedings of the 21st International Esaform Conference on Material Forming:Esaform 2018. https://doi.org/10.1063/1.5034963
Groth S, Engel B, Langhammer K (2018) Algorithm for the quantitative description of freeform bend tubes produced by the three-roll-push-bending process. Prod Eng Res Devel 12:517–524. https://doi.org/10.1007/s11740-018-0795-2
Zhang ZK, Wu JJ, Liang B, Wang MZ, Yang JZ, Muzamil M (2020) A new strategy for acquiring the forming parameters of a complex spatial tube product in free bending technology. J Mater Process Technol 282:116662. https://doi.org/10.1016/j.jmatprotec.2020.116662
Daxin E, Liu YF (2010) Springback and time-dependent springback of 1Cr18Ni9Ti stainless steel tubes under bending. Mater Des 31:1256–1261. https://doi.org/10.1016/j.matdes.2009.09.026
Cheng C, Pan C, Bai XS, Liu CM, Guo XZ (2022) Investigation on the influence of weld position on the deformation behavior of welded tube during free bending process. Int J Adv Manuf Technol 120:2201–2215. https://doi.org/10.1007/s00170-022-08893-y
Kou BF, Li ZS, Zhang Z, Li RQ (2021) Friction and wear properties of hydraulic components with ceramic/steel-to-steel pairs. J Mech Sci Technol 35:3375–3388. https://doi.org/10.1007/s12206-021-0711-0
Xiong H (2019) Research on the forming limit of free bending process of metal tubes. Nanjing University of Aeronautics and Astronautics https://doi.org/10.27239/d.cnki.gnhhu.2019.001753
Gantner P, Harrison DK, De Silva AK, Bauer H (2007) The development of a simulation model and the determination of the die control data for the free-bending technique. Proc Inst Mech Eng, Part B: Journal of Engineering Manufacture 221:163–171. https://doi.org/10.1243/09544054JEM6
Acknowledgements
The authors would like to acknowledge the funding support to this research from the Open Fund of Jiangsu Industrial Perception and Intelligent Manufacturing Equipment Engineering Research Center (No: 2021-04), National Natural Science Foundation of China (No.52105360).
Funding
This work was supported by Open Fund of Jiangsu Industrial Perception and Intelligent Manufacturing Equipment Engineering Research Center (No: 2021–04), National Natural Science Foundation of China (No.52105360).
Author information
Authors and Affiliations
Contributions
All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Zonghui Cheng, Yuanji Shi, and Shaoxin Li. The first draft of the manuscript was written by Cheng Cheng, Song Shu, and Xunzhong Guo. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.
Corresponding author
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Cheng, Z., Li, S., Cheng, C. et al. Investigation on variation characteristics of bent tube axis and determination of bending die motion trajectory in free bending process. Int J Adv Manuf Technol 124, 3371–3389 (2023). https://doi.org/10.1007/s00170-022-10727-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-10727-w