Skip to main content
SpringerLink
Log in

Three-dimensional finite element modeling of rotary-draw bending of copper-titanium composite tube

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

Abstract

The copper-titanium bimetallic composite bent tube, which could integrate the advantages of physical, chemical, and mechanical properties of two materials, shows an urgent application demand prospect in mechanical manufacturing, marine operations, and other industrial fields. This paper develops a research on the modeling of rotary-draw bending of copper-titanium composite tube by using two kinds of grid elements S4R and C3D8R, respectively. The contact problem of base tube and covered tube is set as coulomb friction contact mode, whose optimal friction coefficient is obtained by pressure-shearing experiment and its simulation. The springback model is established by considering the contact action of the two tubes. Finally, the S4R shell FE model is compared with the C3D8R solid FE model from the two aspects of section deformation and springback. It is found that the shell element model is accurate in predicting the springback and section deformation, while the solid element model has a large deviation from the experimental results in predicting the section deformation. In order to gain a deeper understanding of the plastic deformation behavior of the bimetallic composite tube, the tangential stress, equivalent stress, equivalent strain, and damage values have been studied. Results show that (1) there is no significant uneven deformation between the base tube and the covered tube, which will not produce obvious wrinkling and section distortion even without the filling of the mandrel dies. (2) Sliding and stratification are existing between the base tube and the covered tube in the bending process. (3) The force of the dies on the base tube is transmitted through the side surface contact between the base tube and the covered tube. (4) The maximum damage value of the covered tube is larger than that of the base tube. This research will promote the development of precise plastic processing technology and play a role in the research of secondary plastic forming of metal composite tubes.

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

Similar content being viewed by others

References

  1. Wang HF, Han JT, Hao QL (2015) Fabrication of laminated-metal composite tubes by multi-billet rotary swaging technique. Int J Adv Manuf Technol 76:713–719. https://doi.org/10.1007/s00170-014-6302-9

    Article  Google Scholar 

  2. Chen H, Ma HZ, Chen XM, Jiang SF, Wang HJ (2015) Failure analysis of butt weld of bimetal composite pipes. J Fail Anal Prev 15:563–570. https://doi.org/10.1007/s11668-015-9978-8

    Article  Google Scholar 

  3. Tavassolimanesh A, Nia AA (2017) A new approach for manufacturing copper-clad aluminum bimetallic tubes by friction stir welding (FSW). J Manuf Process 30:374–384. https://doi.org/10.1016/j.jmapro.2017.10.010

    Article  Google Scholar 

  4. Lapovok R, Ng HP, Tomus D, Estrin Y (2012) Bimetallic copper-aluminium tube by severe plastic deformation. Scr Mater 66:1081–1084. https://doi.org/10.1016/j.scriptamat.2012.03.004

    Article  Google Scholar 

  5. Li WY, Wen Q, Yang XW, Wang YS, Gao DL, Wang WB (2017) Interface microstructure evolution and mechanical properties of Al/cu bimetallic tubes fabricated by a novel friction-based welding technology. Mater Des 134:383–393. https://doi.org/10.1016/j.matdes.2017.08.065

    Article  Google Scholar 

  6. Jiang WM, Fana ZT, Li C (2015) Improved steel/aluminum bonding in bimetallic castings by a compound casting process. J Mater Process Technol 226:25–31. https://doi.org/10.1016/j.jmatprotec.2015.06.032

    Article  Google Scholar 

  7. Liu XH, Zou WJ, Fu HD, Liu XF, Xie JX (2017) Cu/Ti bimetal composite pipe fabricated by heating rotary swaging forming and its interface, microstructure and properties. Chin J Rare Metals 04:364–370 (in Chinese). https://doi.org/10.13373/j.cnki.cjrm.XY16110005

    Article  Google Scholar 

  8. Liu XH, Lin YL, Fu HD, Liu XF, Xie JX (2017) Preparation of the capillary copper/titanium composite pipe by floating-plug drawing processing and its microstructure and properties. Chin J Eng 39:417–425 (in Chinese). https://doi.org/10.13374/j.issn2095-9389.2017.03.014

    Article  Google Scholar 

  9. Zhai YB, Liu CM, Wang K, Zou MH, Xie Y (2010) Characteristics of two Al based functionally gradient composites reinforced by primary Si particles and Si/in situ Mg2Si particles in centrifugal casting. Trans Nonferrous Metals Soc China 20:361–370. https://doi.org/10.1016/S1003-6326(09)60147-3

    Article  Google Scholar 

  10. Hejazi MM, Divandari M, Taghaddos E (2009) Effect of copper insert on the microstructure of gray iron produced via lost foam casting. Mater Des 30:1085–1092. https://doi.org/10.1016/j.matdes.2008.06.032

    Article  Google Scholar 

  11. Li CZ, Tang HY, Li JS, Yang HB (2013) Numerical simulation of misrun defect of bimetallic composite pipe by investment casting. Appl Mech Mater 251:442–445. https://doi.org/10.4028/www.scientific.net/AMM.251.442

    Article  Google Scholar 

  12. Guo XZ, Wei WB, Xu Y, Abd El-Aty A, Liu H, Wang H, Luo XY, Tao J (2019) Wall thickness distribution of cu–Al bimetallic tube based on free bending process. Int J Mech Sci 150:12–19. https://doi.org/10.1016/j.ijmecsci.2018.10.013

    Article  Google Scholar 

  13. Li H, Yang H, 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 Technol 212:1973–1987. https://doi.org/10.1016/j.jmatprotec.2012.04.022

    Article  Google Scholar 

  14. Wen T (2014) On a new concept of rotary draw bend-die adaptable for bending tubes with multiple outer diameters under non-mandrel condition. J Mater Process Technol 02:311–317. https://doi.org/10.1016/j.jmatprotec.2013.09.019

    Article  Google Scholar 

  15. Liao J, Xue X, Lee MG, Barlat F, Gracio J (2014) On twist springback prediction of asymmetric tube in rotary draw bending with different constitutive models. Int J Mech Sci 89:311–322. https://doi.org/10.1016/j.ijmecsci.2014.09.016

    Article  Google Scholar 

  16. Xue X, Liao J, Vincze G, Gracio JJ (2015) Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tube. J Mater Process Technol 216:405–417. https://doi.org/10.1016/j.jmatprotec.2014.10.007

    Article  Google Scholar 

  17. Liu N, Yang H, Li H, Tao ZJ, Hu X (2015) An imperfection-based perturbation method for plastic wrinkling prediction in tube bending under multi-die constraints. Int J Mech Sci 98:178–194. https://doi.org/10.1016/j.ijmecsci.2015.03.023

    Article  Google Scholar 

  18. 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 82:1569–1580. https://doi.org/10.1007/s00170-015-7468-5

    Article  Google Scholar 

  19. Liu YL, Zhu YX, Dong WQ, Yang H (2013) Springback prediction model considering the variable Young’s Modulus for the bending rectangular 3A21 tube. J Mater Eng Perform 22:9–16. https://doi.org/10.1007/s11665-012-0227-y

    Article  Google Scholar 

  20. 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. https://doi.org/10.1016/j.ijmecsci.2018.02.022

    Article  Google Scholar 

  21. Gearing BP, Moon HS, Anand L (2001) A plasticity model for interface friction application to sheet metal forming. Int J Plast 17:237–271. https://doi.org/10.1016/S0749-6419(00)00034-6

    Article  MATH  Google Scholar 

  22. Xu H (1991) Machinery’s handbook, 1th edn. China Machine Press, Beijing (in Chinese)

    Google Scholar 

  23. Hilberink A, Gresnigt AM, Sluys LJ (2011) Mechanical behaviour of lined pipe during bending, numerical and experimental results compared. ASME 2011 30th international conference on ocean, offshore and Arctic engineering. Am Soc Mech Eng 04:401–412. https://doi.org/10.1115/OMAE2011-49434

    Article  Google Scholar 

  24. Guo XZ, Tao J, Tang QS, Li HG, Bian JM, Li M (2012) Cold push-bending simulation and experiment on TA1-Al bimetallic clad tube. Chin J Nonferrous Metals 22:1053–1062 (in Chinese). https://doi.org/10.19476/j.ysxb.1004.0609.2012.04.010

    Article  Google Scholar 

  25. Kobayashi S, Oh S, Altan T (1989) Metal forming and the finite-element method. Oxford University Press, New York

    Google Scholar 

  26. Kong CM, Liao HY (2016) Analysis on the tearing principle between layers of the cold rolled bi-metal composite pipe. Forging and Stamping Technology 41:142–148 (in Chinese). https://doi.org/10.13330/j.issn.1000-3940.2016.10.027

    Article  Google Scholar 

  27. 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 76:132–143. https://doi.org/10.1016/j.ijmecsci.2013.09.011

    Article  Google Scholar 

Download references

Funding

The research is supported by National Natural Science Foundation of China (No. 51601070), Natural Science Foundation of Jiangsu Province (No. BK20181447), Postdoctoral Science Foundation of Jiangsu Province (No. 1501099B), and Senior Talent Foundation of Jiangsu University (No. 14JDG135).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Jiangsu University, Zhenjiang, China

    Y. X. Zhu, W. Chen, W. B. Tu, Y. Guo & L. Chen

Authors
  1. Y. X. Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. W. Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. W. B. Tu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Y. Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. L. Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Y. X. Zhu.

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

Zhu, Y.X., Chen, W., Tu, W.B. et al. Three-dimensional finite element modeling of rotary-draw bending of copper-titanium composite tube. Int J Adv Manuf Technol 106, 2377–2389 (2020). https://doi.org/10.1007/s00170-019-04781-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04781-0

Keywords

Search

Navigation