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Experimental and FE simulation study on cross-section distortion of rectangular tube under multi-die constraints in rotary draw bending process

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Abstract

The rotary draw bending of thin-walled rectangular tube is a complex process with multi-nonlinearity under multi-die constraints. The constraints of various dies on the cross-section distortion ratio are studied by experiment and the friction coefficients are obtained by twist-compression test. It is found that the effects of bend die, mandrel die and pressure die on cross-section distortion are significant. The significant influencing factors include bend angle, bend radius, clamp pressure, core number and the boost velocity. A three-dimensional finite-elements model of this process is built under the ABAQUS/explicit environment based on the solution of several key techniques, such as model creation, material properties definition, contact boundary condition treating, meshing technology, and it is validated to be credible. Furthermore, the orthogonal experimental design is used to investigate the interactive effects of friction on cross-section distortion ratio, and the optimal combination is obtained.

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Abbreviations

R:

bend radius

h:

the height of rectangular tube before bent

hmin:

the height of tube before bent

t :

thickness of tube

e max :

thickness of tube

e :

mandrel extension

µ:

friction coefficient in tube-die interface

ν :

Poisson’s ratio

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Authors and Affiliations

  1. State Key Laboratory of Solidification Processing, School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Kuanxin Liu, Yuli Liu & He Yang

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  1. Kuanxin Liu
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  2. Yuli Liu
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  3. He Yang
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Correspondence to Yuli Liu.

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Liu, K., Liu, Y. & Yang, H. Experimental and FE simulation study on cross-section distortion of rectangular tube under multi-die constraints in rotary draw bending process. Int. J. Precis. Eng. Manuf. 15, 633–641 (2014). https://doi.org/10.1007/s12541-014-0381-2

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  • DOI: https://doi.org/10.1007/s12541-014-0381-2

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