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Study of Intrusion Bending for Steel Tubes with Thin Wall Thickness

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Abstract

In regard to light-weight structural members for automobiles, attention to hydroforming has been increasing. Intrusion-bending method is well suited to the preliminary bending of hydroformed structural members of automobiles, because straight tubes can be bent into three-dimensional forms by this new method. However, in the case of tubes with a thin wall thickness, wrinkling remains a problem. In this report, application of intrusion bending method to tubes with extremely low ratios of wall thickness to outer diameter (from 1.2 to 1.9%), and whose steel grades are SSPDX, SAFC440R, and SAFC590T was investigated. A summary of this study is as follows. Effects of steel grades and wall thickness ratios on wrinkle formation, eccentricity, and ovality are studied. Relationships between wrinkle generation and gyro movement are investigated.

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Abbreviations

A :

revolution angle of gyro (°)

B :

rotational angle of gyro (°)

A max :

maximum revolution angle of gyro (°)

B max :

maximum rotation angle of gyro (°)

α:

gyro angle ratio (ratio of A-B)

D :

outer diameter of tube before bending (mm)

D 1 :

outer diameter of bent tube along vertical axis (mm)

D 2 :

outer diameter of bent tube along horizontal axis (mm)

ΔD :

(D 2 − D 1) deviation of D 2 and D 1 of bent tube (mm)

ΔD/D :

ovality of outer diameter

EL:

elongation of test specimen

R :

bending radius (mm)

R/D :

bending radius ratio

t :

wall thickness of tube before bending (mm)

t/D :

ratio of wall thickness to outer diameter

t 1 :

wall thickness of bent tube at extrados (mm)

t 2 :

wall thickness of bent tube at intrados (mm)

Δt :

(t 2 − t 1) deviation of t 2 and t 1 of bent tube (mm)

Δt/t :

eccentricity of wall thickness

TS:

tensile strength of test specimen (MPa)

YS:

yield stress of test specimen (MPa)

x :

distance pusher advanced (mm)

References

  1. M. Mizumura, Y. Kuriyama, T. Sugi, M. Fukutoku, and H. Naoi, Effects Manufacturing Conditions on Deformation Behavior of Bent Pipes, Proceedings of the 10th International Symposium on Processing and Fabrication of Advanced Materials, Session 9 Microstructure Property Relationships, November 2001, p 1–13

  2. M. Murata, Y. Uemura, and H. Suzuki, New Penetration Bending of Circular Tube Using Die, J. Jpn. Soc. Technol. Plasticity, 1990, 31(357), p 264–269

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  3. OPTON CO., LTD. in Japan, http://www.opton.co.jp Catalog, RP-80-AC of PIPE MULTI BENDER

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Author information

Authors and Affiliations

  1. Hosei University, Tokyo, Japan

    Hisashi Naoi & Naoki Kitakami

  2. Nippon Steel Corp., Tokyo, Japan

    Masaaki Mizumura & Yukihisa Kuriyama

Authors
  1. Hisashi Naoi
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  2. Naoki Kitakami
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  3. Masaaki Mizumura
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  4. Yukihisa Kuriyama
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Corresponding author

Correspondence to Hisashi Naoi.

Additional information

This article was presented at Materials Science & Technology 2007, Automotive and Ground Vehicles symposium held September 16-20, 2007, in Detroit, MI.

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Naoi, H., Kitakami, N., Mizumura, M. et al. Study of Intrusion Bending for Steel Tubes with Thin Wall Thickness. J. of Materi Eng and Perform 17, 376–381 (2008). https://doi.org/10.1007/s11665-008-9223-7

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  • DOI: https://doi.org/10.1007/s11665-008-9223-7

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