An innovative PVC mandrel for controlling the cross-sectional deformation of double-ridged rectangular tube in rotary draw bending

  • Honglie Zhang
  • Yuli LiuEmail author


In order to control the cross-sectional deformation of double-ridged rectangular tube (DRRT) in rotary draw bending (RDB), a PVC mandrel just supporting the back of ridge grooves was introduced. The characteristics of cross-sectional deformation of DRRT and its evolution with the new PVC mandrel were revealed numerically by comparing with that with the mandrel-core die. In order to evaluate the application scope of the new PVC mandrel, the cross-sectional deformation for different specifications of DRRT in RDB were also researched. The results show that: (1) the flange sagging Δh, space deformation between ridges Δd, and width deformation of inner ridge groove Δw by using the new PVC mandrel can be better controlled than that by using the mandrel-core die. But the width deformation of the outer ridge groove ΔW gets a little larger; (2) by using the new PVC mandrel, the maxima of absolute values of Δh and Δw and the maximum of ΔW all increase firstly with the process of bending and then change little when the bending angle is larger than 60°, which are consistent with the variation of the peak value of tangent stress on the flange, while the maximum of absolute value of Δd increases continuously. (3) For small-sized DRRT, its cross-sectional deformation can be well controlled by using the new PVC mandrel. However, with the increase of dimension of DRRT, the cross-sectional deformation of DRRT increases obviously, and its distribution is extremely non-homogeneous.


Double-ridged rectangular tube Rotary draw bending Cross-sectional deformation PVC mandrel Back of ridge grooves 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.



The authors would like to thank the Science and Technology Project of Shenzhen (No.JCYJ20170306160003433), National Natural Science Foundation of China (No.51375392), and 111 Project (No. B08040) for the support given to this research.


  1. 1.
    Xiao YH, Liu YL, Yang H (2014) Research on cross-sectional deformation of double-ridged rectangular tube during H-typed rotary draw bending process. Int J Adv Manuf Technol 73(9):1789–1798. CrossRefGoogle Scholar
  2. 2.
    Zhao GY, Liu YL, Zhang RY, Yang H (2014) Optimal design of process parameters of rotary-draw bending process for thin-walled rectangular tube of aluminum alloy. Proc IMechE B J Eng Manuf 228(11):1442–1448. CrossRefGoogle Scholar
  3. 3.
    Gu RJ, Yang H, Zhan M, Li H, Wang GX (2005) Effect of mandrel on cross sectional quality of thin-walled tube on numerical controlled bending. Trans Nonferrous Metals Soc China 15(6):1264–1274Google Scholar
  4. 4.
    Zhu YX, Liu YL, Yang H (2012) Sensitivity of springback and section deformation to process parameters in rotary draw bending of thin-walled rectangular H96 brass tube. Trans Nonferrous Metals Soc China 22:2233–2240. CrossRefGoogle Scholar
  5. 5.
    Li H, Yang H, Zhan M, Sun ZC, RJ G (2007) Role of mandrel in NC precision bending process of thin-walled tube. Int J Mach Tools Manuf 47:1164–1175. CrossRefGoogle Scholar
  6. 6.
    Xiao YH, Liu YL, Yang H, Ren JH (2014) Optimization of processing parameters for double-ridged rectangular tube rotary draw bending based on grey relational analysis. Int J Adv Manuf Technol 70(9):2003–2011. CrossRefGoogle Scholar
  7. 7.
    Peng YH, Tang D, Li DY (2008) Study on the influence of mandrel type on copper tube rotary draw bending. Int J Mater Prod Technol 32(4):406–422. CrossRefGoogle Scholar
  8. 8.
    Ancellotti S, Benedetti M, Fontanari V, Slaghenaufi S, Tassan M (2016) Rotary draw bending of rectangular tubes using a novel parallelepiped elastic mandrel. Int J Adv Manuf Technol 85(5):1089–1103. CrossRefGoogle Scholar
  9. 9.
    Utsumi N, Sakaki S (2002) Countermeasures against undesirable phenomena in the draw-bending process for extruded square tubes. J Mater Process Technol 123:264–269CrossRefGoogle Scholar
  10. 10.
    Zhu YX, Liu YL, Li HP, Yang H (2013) Comparison between the effects of PVC mandrel and mandrel-cores die on the forming quality of bending rectangular H96 tube. Int J Mech Sci 72:132–143. CrossRefGoogle Scholar
  11. 11.
    Zhang HL, Liu YL, Yang H (2016) Deformation behaviors of double-ridged rectangular H96 tube in rotary draw bending under different mandrel types. Int J Adv Manuf Technol 82(9):1569–1580. CrossRefGoogle Scholar
  12. 12.
    Li HP, Liu YL, Zhu YX, Yang H (2014) Influence of mandrel on cross section deformation of double-ridge rectangular tube in rotary-draw bending process. Mater Sci Technol 22(3):46–53 (In Chinese)Google Scholar
  13. 13.
    Alves LM, Pardal TCD, Martins PAF (2009) Forming of thin-walled hollow spheres using sacrificial polymer mandrels. Int J Mach Tools Manuf 49(6):521–529. CrossRefGoogle Scholar
  14. 14.
    Alves LM, Martins PAF (2008) Single-stage nosing of thin-walled tubes into hollow spheres using a die. J Strain Anal Eng Des 43:205–216. CrossRefGoogle Scholar
  15. 15.
    Sun QF, Chen XQ, Lu M (2013) Analysis field pattern with mutative ridge of double-ridge waveguide. Laser J 34(6):32–33 (In Chinese)Google Scholar
  16. 16.
    Paulsen F, Welo T (2001) Cross-sectional deformations of rectangular hollow sections in bending: part II—analytical models. Int J Mech Sci 43:131–152CrossRefzbMATHGoogle Scholar
  17. 17.
    Zhang HL, Liu YL, Yang H (2017) Study on the ridge grooves deformation of double-ridged waveguide tube in rotary draw bending based on analytical and simulative methods. J Mater Process Technol 243:100–111. CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  1. 1.Research & Development Institute of Northwestern Polytechnical University in ShenzhenShenzhenPeople’s Republic of China
  2. 2.State Key Laboratory of Solidification Processing, School of Materials Science and EngineeringNorthwestern Polytechnical UniversityXi’anPeople’s Republic of China

Personalised recommendations