Skip to main content
SpringerLink
Log in

In-process measurement of springback in tube rotary draw bending

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Rotary draw bending of tubes allows repeatable and accurate manufacturing with narrow bending radii and high production rates, thanks to modern CNC controlled electrical machines. However, springback still represents one the main issues especially in small production batches or when the geometrical and mechanical properties of the raw profiles are not constant within the batch. In-process inertial measurements may allow the close-loop process control of the bending angle and, potentially, offer the possibility to compensate the springback by a real-time tuning of the bending. The paper focuses on a newly developed in-process measurement technique and presents an assessment of in-process inertial springback measurements. The springback of bent tubes is investigated as a function of the measurement gauge position and of the cross-section strain distribution along the bend.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17

Similar content being viewed by others

Data availability

Data and materials are not available since they are covered by confidentiality.

References

  1. He Y, Heng L, Zhiyong Z, Mei Z, Liu J, Guangjun L (2012) Advanced and tends on tube bending forming technologies. Chinese J Aeronaut 25:1–12

    Article  Google Scholar 

  2. Kleiner M, Geiger K, Klaus A (2003) Manufacturing of lightweight components by metal forming. CIRP Annals Manuf Technol 52:521–542

    Article  Google Scholar 

  3. Semiatin SL (1996) ASM handbook volume 14, Forming and forging. ASM International, Ohio

  4. Mentella A, Strano M, Gemignani R (2008) A new method for feasibility study and determination of the loading curves in the rotary-draw bending process. Int J of Mat Form 1:165–168

    Article  Google Scholar 

  5. Albertelli P, Strano M (2017) Tube bending machine modelling for assessing the energy savings of electric drivers technology. J Clean Prod 154:83–93

    Article  Google Scholar 

  6. Al-Qureshi HA (1999) Elastic-plastic analysis of tube bending. Int J Mach Tools Manuf 39:87–104

    Article  Google Scholar 

  7. Murata M, Kuboki T, Takahashi K, Goodarzi M, Jin Y (2008) Effect of hardening exponent on tube bending. J Mat Process Technol 201:189–192

    Article  Google Scholar 

  8. Tang NC (2000) Plastic-deformation analysis in tube bending. Int J Press Vessel Pip 77:751–759

    Article  Google Scholar 

  9. Zhan M, Yang H, Huang L, Gu R (2006) Springback analysis of numerical control bending of thin-walled tube using numerical-analytical method. J Mater Process Tech 177:197–201

    Article  Google Scholar 

  10. El Megharbel A, El Nasser G, El Domiaty A (2008) Bending of tube and section made of strain-hardening materials. J Mater Process Tech 203:372–380

    Article  Google Scholar 

  11. Zhan M, Wang Y, Yang H, Long H (2016) An analytic model for tube bending springback considering different parameter variations of Ti-alloy tubes. J Mater Process Tech 236:123–137

    Article  Google Scholar 

  12. Daxin E, Zhiping G, Chen J (2012) Influence of additional tensile force on springback of tube under rotary draw bending. J Mater Eng Perform 21:2316–2322

    Article  Google Scholar 

  13. Tang D, Li D, Yin Z, Peng Y (2009) Roles of surface booster system on bending of thin-walled copper tube. J Mater Eng Perform 18:369–377

    Article  Google Scholar 

  14. Gu RJ, Yang H, Zhan M, Li H, Li HW (2008) Research on the springback of thin-walled tube NC bending based on the numerical simulation of the whole process. Comput Mat Sci 42:537–549

    Article  Google Scholar 

  15. Zhu YX, Chen W, Li HP, Liu YL, Chen L (2018) Springback study of RDB of rectangular H96 tube. Int J Mech Sci 138–139:282–294

    Article  Google Scholar 

  16. Zhu YX, Liu YL, Yang H (2015) Effect of mandrel-cores on springback and sectional deformation of rectangular H96 tube NC bending. Int J Adv Manuf Technol 78:351–360

    Article  Google Scholar 

  17. Han C, Feng H, Yuan SJ (2017) Springback and compensation of bending for hydroforming of advanced high-strength steel welded tubes. Int J Adv Manuf Technol 89:3619–3629. https://doi.org/10.1007/s00170-016-9319-4

    Article  Google Scholar 

  18. Polyblank JA, Allwood JM, Duncan SR (2014) Closed-loop control of products properties in metal forming: a review and prospectus. J Mater Process Tech. 214:2333–2348

    Article  Google Scholar 

  19. Allwood JM, Duncan SR, Cao J, Groche P, Hirt G, Kinsey B, Kuboki T, Liewald M, Sterzing A, Tekkaya AE (2016) Closed-loop control of product properties in metal forming. CIRP Annals Manuf Technol 65:573–596

    Article  Google Scholar 

  20. Pan WF, Wang TR, Hsu CM (1998) A curvature-ovalization measurement apparatus for circular tubes under cyclic bending. Exp Mech 38:99–102

    Article  Google Scholar 

  21. Chatti S, Dirksen U, Kleiner M (2004) Optimization of the design and manufacturing process of bent profiles. J Mech Behav Mater 15:437–444

    Article  Google Scholar 

  22. Ha T, Ma J, Blindheim J, Welo T, Ringer G, Wang J (2020) In-line springback measurement for tube bending using a laser system. Procedia Manuf 47:766–773

    Article  Google Scholar 

  23. Löbbe C, Hoppe C, Becker C, Tekkaya AE (2015) Closed loop springback control in progressive die bending by induction heating. Int J of Precis Eng and Manuf 16:2441–2449

    Article  Google Scholar 

  24. Kinnel P, Rymer T, Hodgson J, Justham L, Jackson M (2017) Autonomous metrology for robot mounted 3D vision systems. CIRP Annals Manuf Technol 66:483–486

    Article  Google Scholar 

  25. Ghiotti A, Simonetto E, Bruschi S, Bariani PF (2017) Springback measurement in three roll push bending process of hollow structural sections. CIRP Annals Manuf Technol 66:289–292

    Article  Google Scholar 

  26. Simonetto E, Ghiotti A, Bruschi S (2017) Dynamic detection of tubes wrinkling in three roll push bending. Procedia Eng 207:2316–2321

    Article  Google Scholar 

  27. Simonetto E, Ghiotti A, Bruschi S, Gemignani R (2017) Dynamic detection of tubes wrinkling in tube rotary draw bending. Procedia Manuf 10:319–328

    Article  Google Scholar 

  28. Simonetto E, Ghiotti A, Bruschi S (2015) Feasibility of motion-capture techniques applied in tube bending. Key Eng Mater 651:1198–1133

    Google Scholar 

  29. Li H, Yang F, Song FF, Zhan M, Li GJ (2012) Springback characterization and behaviors of high-strength Ti–3Al–2.5V tube in cold rotary draw bending. J Mater Process Tech 212:1973–1987

  30. Li H, Yang H, Song F, Li G (2013) Springback nonlinearity of high-strength titanium alloy tube mandrel bending. Int J Precis Eng Manuf 3:429–438. https://doi.org/10.1007/s12541-013-0059-1

    Article  Google Scholar 

  31. Ancelotti 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 85:1089–1103. https://doi.org/10.1007/s00170-015-8000-7

    Article  Google Scholar 

  32. Farhadi A, Nayebi A (2020) Springback analysis of thick-walled tubes under combined bending-torsion loading with consideration of nonlinear kinematic hardening. Production Eng 14:135–145. https://doi.org/10.1007/s11740-020-00951-2

    Article  Google Scholar 

  33. Xue X, Liao J, Vincze G, Pereira AB (2018) Control strategy of twist springback for aluminium alloy hybrid thin-walled tube under mandrel-rotary draw bending. Int J Mater From 11:311–323. https://doi.org/10.1007/s12289-017-1346-7

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, University of Padua, Via Venezia 1, 35131, Padova, Italy

    Enrico Simonetto, Andrea Ghiotti & Stefania Bruschi

Authors
  1. Enrico Simonetto
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Andrea Ghiotti
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Stefania Bruschi
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Enrico Simonetto was in charge of the development of the experimental and simulative work. Andrea Ghiotti developed the concept of the paper and was in charge of the paper writing. Stefania Bruschi had the role of revision and paper improvement.

Corresponding author

Correspondence to Andrea Ghiotti.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Consent to participate

Not applicable

Consent to publish

Not applicable

Ethic approval

Not applicable

Code availability

Numerical simulation software is property of the respective software houses. No other software developed for the data analysis is available.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Simonetto, E., Ghiotti, A. & Bruschi, S. In-process measurement of springback in tube rotary draw bending. Int J Adv Manuf Technol 112, 2485–2496 (2021). https://doi.org/10.1007/s00170-020-06453-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-06453-w

Keywords

Search

Navigation