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Inhibiting thinning in tube bending by a superposition effect under a boosting movement

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Abstract

Pressure die boost effectively inhibits the thinning in the manufacturing process of aerospace tubes because it can produce a superposition effect of material compensation and friction. This phenomenon attracts lots of scholars. The related research uses the finite element and experimental method to analyze the tube thinning with and without a boost. The effects of boosting velocity and friction on the outer wall thickness of the tube are studied. Results show that frictional force generated by the boost and the material compensation effect combines to resist the outer wall thinning during the bending process. When the boosting velocity is higher than the tube bending linear velocity, the frictional force of the boost generates a specific compressive stress, which weakens the tensile stress during the bending process. In the meantime, the boosting effect transfers the material from the feed section to the bending section, compensating for the thinning of the tube wall during the bending process. A new theoretical model of tube bending and thinning under boost conditions is proposed to explain this coupling effect. The relative error between the new theoretical model and the experimental value is less than 1.5%, and the accuracy is improved by 5.3% compared with the traditional no-boost condition. The research overcomes the poor accuracy of the existing thinning model when fitting to boosted conditions and reveals the boosted effect’s mechanism on tube thinning.

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Funding

This research is financially supported by the Natural Science Foundation of Hunan Province, China (Grant No. 2023JJ30258, 2023JJ50018) and the Key Lab of Advanced Measurement and Test Technology for Aviation Propulsion System, Liaoning Province (Grant No. AMTAPS202301).

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Authors and Affiliations

  1. Hunan Provincial Key Laboratory of Health Maintenance for Mechanical Equipment, Hunan University of Science and Technology, Xiangtan, 411201, China

    Hao Fang, Zhineng Wang & Guangfu Bin

  2. Key Laboratory of Advanced Measurement and Test Technique for Aviation Propulsion System, Shenyang Aerospace University, Shenyang, 110136, People’s Republic of China

    Zhineng Wang

  3. Zhejiang King-Mazon Intelligent Manufacturing Corp. Ltd, Lijiang, 321400, China

    Zhineng Wang, Weiming Ling & Yaocheng Ling

  4. Hydraulic Engineering Department, Hanoi University of Civil Engineering, 55 Giai Phong, Hanoi, Vietnam

    Cong Trieu Tran

Authors
  1. Hao Fang
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  4. Weiming Ling
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Contributions

Hao Fang: investigation, software, measurements, data analysis and interpretation, model development, writing—original draft, formal analysis. Zhineng Wang: conceptualization, methodology, writing—review and editing, project administration, supervision. Guangfu Bin: conceptualization, methodology, investigation, project administration, supervision. Weiming Lin: conceptualization, methodology, investigation. Yaochen Lin: conceptualization, methodology, investigation. Cong Trieu Tran: conceptualization, methodology, investigation.

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Correspondence to Zhineng Wang.

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Fang, H., Wang, Z., Bin, G. et al. Inhibiting thinning in tube bending by a superposition effect under a boosting movement. Int J Adv Manuf Technol 130, 5329–5344 (2024). https://doi.org/10.1007/s00170-024-13047-3

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