Skip to main content
SpringerLink
Log in

A simplified formulation for predicting wrinkling of thin-wall elbow tube in granular media–based push-bending process

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

Abstract

Wrinkling is the key forming defect in thin-wall tube bending process, when the wall thickness-to-diameter ratio is smaller than 0.01. The granular media-based thin-wall elbow push-bending process involves filling a tube with spherical particles and pushing the tube into a die to bend a tubular blank into an elbow shape. If the wall thickness of tube is smaller than the particle size, wrinkling significantly depends on micro contact force distribution in granular media, and the granular media cannot be approximately simulated by FEM. In the present paper, an elbow tube with 0.3 mm wall thickness, 30 mm outer diameter, and 90 mm bending radius is formed by granular media-based push-bending process. The wrinkling is investigated; especially, the micro contact force distribution at the initial buckling location is observed based on a 3D FEM-DEM coupling model. In the coupling model, FEM is used to simulate bending deformation of tubular blank, and DEM is used to simulate micro contact forces of particle flow. Finally, a simplified formulation is proposed for predicting wrinkling of thin-wall elbow tube in granular media-based push-bending process and validated by experiment of an elbow tube with 0.7 mm wall thickness, 70 mm outer diameter, and 105 mm bending radius.

Graphical abstract

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

Similar content being viewed by others

Data availability

The data sets supporting the results of this article are included within the article.

References

  1. Yang H, Li H, Zhang ZY et al (2012) Advances and trends on tube bending forming technologies. Chin J Aeronaut 25:1–12

    Article  Google Scholar 

  2. Hashmi MSJ (2006) Aspects of tube and pipe manufacturing processes: meter to nanometer diameter. J Mater Process Technol 179:5–10

    Article  Google Scholar 

  3. Yang H, Li H, Zhang ZY et al (2012) Advances and trends on tube bending forming technologies. J Plast Eng 8:83–85

    Google Scholar 

  4. Vasilikis D, Karamanos SA (2012) Mechanical behavior and wrinkling of lined pipes. Int J Solids Struct 49:3432–3446

    Article  Google Scholar 

  5. Abela JM, Gardner L (2012) Elastic buckling of elliptical tubes subjected to generalized linearly varying stress distributions. Thin-Walled Struct 58:40–50

    Article  Google Scholar 

  6. Nia AA, Nejad KF, Badnava H et al (2012) Effects of buckling initiators on mechanical behavior of thin-walled square tubes subjected to oblique loading. Thin-Walled Struct 59:87–96

    Article  Google Scholar 

  7. Teng BG, Hu L, Liu G et al (2012) Wrinkling behavior of hydro bending of carbon steel Al alloy bilayered tubes. Trans Nonferrous Metals Soc China 22:560–565

    Article  Google Scholar 

  8. Zeng Y, Li Z (2002) Experimental research on the tube push-bending process. J Mater Process Technol 122:237–240

    Article  Google Scholar 

  9. Baudin S, Ray P, Mac Donald BJ et al (2004) Development of a novel method of tube bending using finite element simulation. J Mater Process Technol 153:128–133

    Article  Google Scholar 

  10. Kahnamouei JT, Behjat B (2010) Modeling and experimental validation of the effect of sand filling on avoiding wrinkling phenomenon in thin-walled tube bending process. In: ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers, pp 799–803

  11. Grüner M, Merklein M (2010) Numerical simulation of hydro forming at elevated temperatures with granular material used as media compared to the real part geometry. Int J Mater Form 3:279–282

    Article  Google Scholar 

  12. Chen H, Güner A, Khalifa NB, Tekkaya AE (2016) Granular media-based tube press hardening. J Mater Process Technol 228:145–159

    Article  Google Scholar 

  13. Chen H, Hess S, Haeberle J, Pitikaris S, Born P, Güner A, Sperl M, Tekkaya AE (2016) Enhanced granular medium-based tube and hollow profile press hardening. CIRP Ann Manuf Technol 65:273–276

    Article  Google Scholar 

  14. Dong GJ, Zhao CC, Peng YX et al (2015) Hot granules medium pressure forming process of AA7075 conical parts. Chin J Mech Eng 28:580–591

    Article  Google Scholar 

  15. Dong GJ, Bi J, Du B et al (2017) Research on AA6061 tubular components prepared by combined technology of heat treatment and internal high pressure forming. J Mater Process Technol 242:126–138

    Article  Google Scholar 

  16. Du B, Zhao CC, Dong GJ et al (2017) FEM-DEM coupling analysis for solid granule medium forming new technology. J Mater Process Technol 249:108–117

    Article  Google Scholar 

  17. Liu H, Zhang SH, Song HW, Shi GL, Cheng M (2019) 3D FEM-DEM coupling analysis for granular-media-based thin-wall elbow tube push-bending process. Int J Mater Form 12:985–994

    Article  Google Scholar 

  18. H.D. Hibbit,B.I. Karlsson, P. Sorensen. 2007, Theory Manual, ABAQUS, Version 6.7, Providence, RI, USA

  19. Tsuji Y, Tanaka T, Ishida T (1992) Lagrangian numerical-simulation of plug flow of cohesionless particles in a horizontal pipe. Powder Technol 71:239–250

    Article  Google Scholar 

  20. Christofferson J, Mehrabadi MM, Nemat-Nassar S (1981) A micromechanical description on granular material behavior. ASME: J Appl Mechan 48:339–344

    MATH  Google Scholar 

  21. Rothenburg L, Selvadurai APS (1981) Micromechanical definitions of the Cauchy stress tensor for particular media. In: Selvadurai APS (ed) Mechanics of Structured Media. Elsevier, Amsterdam, pp 469–486

    Google Scholar 

  22. Timoshenko S, Gere JM (1961) Theory of Elastic Stability, Second edn. McGraw Hill, New York, NY

    Google Scholar 

Download references

Funding

The present work is funded by the project of Suzhou Key Laboratory Foundation (SZS201815).

Author information

Authors and Affiliations

  1. Department of Precision Manufacturing Engineering, Suzhou Vocational Institute of Industrial Technology, 1 Zhineng Avenue, Suzhou, 215104, People’s Republic of China

    Hai Liu, Yun-Peng Ding, Gao-Lian Shi & Zhe Geng

  2. Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang, 110016, People’s Republic of China

    Shi-Hong Zhang

Authors
  1. Hai Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shi-Hong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yun-Peng Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Gao-Lian Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhe Geng
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The persons making contributions on this work have been listed in author information.

Corresponding authors

Correspondence to Shi-Hong Zhang or Yun-Peng Ding.

Ethics declarations

Ethical approval

Neither the entire paper nor any part of its content has been published or has been accepted elsewhere. It is not being submitted to any other journal.

Consent to participate

The authors consent to participate in this work.

Consent for publication

The authors consent to publish this paper on “The International Journal of Advanced Manufacturing Technology”.

Competing interests

The authors declare no competing interests.

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

Liu, H., Zhang, SH., Ding, YP. et al. A simplified formulation for predicting wrinkling of thin-wall elbow tube in granular media–based push-bending process. Int J Adv Manuf Technol 115, 541–549 (2021). https://doi.org/10.1007/s00170-021-07168-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07168-2

Keywords

Search

Navigation