Article
Engineering, Manufacturing
Enrico Simonetto, Andrea Ghiotti, Stefania Bruschi
Summary: This paper proposes a method of manufacturing high strength steel tubular components using a high temperature rotary draw bending process, supported by a fully coupled thermo-mechanical-metallurgical numerical model. The model was experimentally validated and proved the optimization of material formability and achievement of the target microstructure, providing feasibility for manufacturing lightweight components.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Jun Fang, Fang Ouyang, Shiqiang Lu, Kelu Wang, Xuguang Min, Botao Xiao
Summary: The elastic modulus varies with plastic deformation, playing a crucial role in simulating tube bending. By embedding this variation into ABAQUS software, the prediction accuracy of springback parameters can be significantly improved.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2021)
Article
Automation & Control Systems
Enrico Simonetto, Andrea Ghiotti, Stefania Bruschi
Summary: Rotary draw bending of tubes with modern CNC controlled machines allows for high production rates, but springback remains a major issue. The study focuses on the impact of measurement gauge position and cross-section strain distribution on the springback of bent tubes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Andrea Ghiotti, Enrico Simonetto, Stefania Bruschi
Summary: Manufacturing hollow section profiles using high strength metallic alloys may face drawbacks such as springback, reduced formability, and wrinkling, which can be significantly reduced by localized heating. An analytical approach is proposed in the paper to predict stress and strain distributions in the cross-section and their impact on springback, with experimental and numerical validations confirming the model's reliability.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Civil
Gholamali Naderi, Seyed Ebrahim Moussavi Torshizi, Seyed Houssain Dibajian
Summary: This paper investigates the wrinkling issue of tight fit pipe (TFP) in rotary-draw bending(RDB), where TFP is a double-walled pipe with a corrosion-resistant alloy liner fitted inside an outer carbon steel pipe through a thermal-hydraulic manufacturing process. A 3D elastic-plastic finite element (FE) model is developed to simulate the manufacturing process, bending analysis, and springback analysis of the two-layer pipe. Contact pressure during the process is monitored by histogram analysis to predict wrinkling, and the best bending angle is obtained to minimize the possibility of wrinkling in the inner pipe.
THIN-WALLED STRUCTURES
(2023)
Article
Automation & Control Systems
Taekwang Ha, Torgeir Welo, Geir Ringen, Jyhwen Wang
Summary: Rotary draw bending is a commonly used metal forming technique, where springback compensation is crucial. An on-machine measurement technique using affordable laser and webcam for real-time springback measurement has been developed. Experimental results demonstrate the feasibility of this new technique for real-time springback measurement in Industry 4.0.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Hailong Liu, Yuli Liu
Summary: The study found that the cross-section deformation of heterogeneous rectangular welded tube is influenced by the yield criteria, with Hill'48 being able to describe its anisotropic characteristics well and appropriate for predicting deformation in RDB.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Automation & Control Systems
Hong Sun, Heng Li, Fangke Gong, Yuli Liu, Guangjun Li, Mingwang Fu
Summary: This study investigated the influence of different filler materials and parameters on the wrinkling behavior of aluminum alloy double-layered gap tube. It was found that hard and tough fillers have a significant inhibitory effect on wrinkling, and decreasing assembly clearance and increasing thickness ratio can effectively reduce wrinkling degree.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Mengyu Fu, Zili Wang, Shuyou Zhang, Xiaojian Liu, Yaochen Lin, Le Wang
Summary: A novel theory is proposed for fitting the full-cross-section deformation characterization of Cu/Al bimetallic tubes under Rotary Draw-Bending, showing remarkable agreement between theoretical and experimental profiles with significantly reduced errors. The study also reveals that the representative parameters of full-cross-section deformation are differently affected by the wall-thickness variations.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Xinwei Wang, Jie Xu, Minghan Ding, Yanhu Zhang, Zhenlong Wang, Bin Guo, Debin Shan
Summary: This study developed a three-dimensional finite element model of electrically-assisted rotary-draw bending of 6063 aluminum alloy micro-tubes using the implicit method in ABAQUS. The effects of process parameters such as micro-tube diameter, bending radius, current density, and electrical load path on bending defects were studied. The results showed that cross-sectional distortion could be improved by adjusting the current path in the micro-tube bending process.
Article
Automation & Control Systems
Zhenbiao Sun, Chunmei Liu, Xunzhong Guo, Zushu Huang, Shuo Zheng, Cheng Cheng, Jie Tao, Ali Abd El-Aty
Summary: This study proposes a novel robot-based tube bending forming technology and investigates its forming mechanism and characteristics using finite element modelling. The obtained results show that the robot-based tube bending forming process improves the stress, strain, and thickening rate of the bent tube compared to traditional rotary draw bending.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Sigmund A. Tronvoll, Jun Ma, Torgeir Welo
Summary: This paper, as the first study in the field of CB, investigates the difference between RDB and CB in terms of manufacturing bends. The experiments show that CB is capable of producing bends with quality similar to RDB, but with increased deformation of the cross section.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Computer Science, Interdisciplinary Applications
Zengkun Zhang, Dongru Li, Jianjun Wu, Muzamil Muhammad, Yang Li
Summary: This study investigates the deformation principles of an eccentric tube in the rotary draw bending process and explores ways to reduce the wall thickness difference between inner and outer diameters.
ENGINEERING COMPUTATIONS
(2023)
Article
Automation & Control Systems
Jicai Liang, Tian Liang, Yi Li, Ce Liang
Summary: This paper investigates the bending of rectangular ribbed section profiles using the RDB process and develops a novel mandrel solution to address wrinkling defects. Experimental measurements and calculations confirm the effectiveness of the new mandrel design in reducing wrinkling in bending operations.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Gholamali Naderi, Seyed Houssain Dibajian, Seyed Ebrahim Moussavi Torshizi, Amirreza Masoumian, Martin Stockinger
Summary: This paper investigates the bending of a Tight Fit Pipe (TFP) and develops a new plugin for efficient simulation of the production and bending processes, evaluating the final bending quality. Experimental validation confirms the accuracy and feasibility of the plugin, showing good agreement between the experimental results and the results presented by the plugin.
INTERNATIONAL JOURNAL OF PRESSURE VESSELS AND PIPING
(2022)
Article
Automation & Control Systems
Tong Wen, Chen Yang, Suo Zhang, Lantao Liu
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2015)
Article
Automation & Control Systems
Tong Wen, Wen-Xue Ou, Qing Liu, Peng Zhang, Chen Yang
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2015)
Article
Automation & Control Systems
Tong Wen, Qian Huang, Qing Liu, Wen-Xue Ou, Suo Zhang
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2016)
Article
Metallurgy & Metallurgical Engineering
Tong Wen, Shi-yao Liu, Shi Chen, Lan-tao Liu, Chen Yang
TRANSACTIONS OF NONFERROUS METALS SOCIETY OF CHINA
(2015)
Article
Automation & Control Systems
Tong Wen, Xia Chen, Jie Zheng, Jian Qing, Ze-xu Tang
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2017)
Article
Engineering, Industrial
Tong Wen, Suo Zhang, Jie Zheng, Qian Huang, Qing Liu
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2016)
Article
Metallurgy & Metallurgical Engineering
Wen Tong, Liu Lan-tao, Huang Qian, Chen Xia, Fang Ji-zhao
JOURNAL OF CENTRAL SOUTH UNIVERSITY
(2018)
Article
Engineering, Industrial
C. Yang, T. Wen, L. T. Liu, S. Zhang, H. Wang
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2014)
Article
Automation & Control Systems
Xia Chen, Tong Wen, Jin Hu, Meng Zhang, Jizhao Fang
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2019)
Article
Metallurgy & Metallurgical Engineering
Zheng-hua Deng, Tong Wen, Jian-hao You, Kang-kang Du, Lei Sun
JOURNAL OF CENTRAL SOUTH UNIVERSITY
(2020)
Article
Automation & Control Systems
Youcheng Pan, Tong Wen, Yin Zhou, Jianhao You, Haoxing Tang, Xia Chen
Summary: Roller clinching is a variation of conventional clinching that utilizes rotational tool movement, with the joining quality significantly influenced by tooling geometries and motions. The study found that roller geometry plays a significant role in the formation of interlocks on the front/rear sides of joints, while the impact on the lateral sides is minimal. Additionally, changes in roller diameter, diameter difference, and clearance difference can affect the connection strength and quality of the joints.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Haoxing Tang, Tong Wen, Yin Zhou, Fan Yang, Yu Zheng
Summary: This paper proposes a finite element method (FEM) model considering nonuniform material properties to reveal strain transfer and reproduce diffuse instability in sheet metal forming. The model assigns discrete material properties conforming to random distribution functions to elements in FEM based on microhardness testing. The digital image correlation (DIC) method is used to validate the model with physical experiments. The influences of random distributions of mechanical properties and mesh size effects on simulation results are also investigated.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Automation & Control Systems
Tong Wen, Longqin Liu, Xu Wang, Yu Zheng, Fan Yang, Yin Zhou
Summary: A new structure of zinc-based alloy dies for sheet metal forming was proposed, where the weak features of the die blocks are reinforced by selective laser melting steel inlays. This method improves the forming quality and durability of the tool.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Yin Zhou, Tong Wen, Xia Chen, Longqin Liu, Fan Yang, Yu Zheng
Summary: Structures with curved holes are highly valuable in industrial applications, but achieving the formation of integral curved holes remains a significant challenge. In this study, a novel methodology called Bulk Forming of Curved Hole (BFCH) was proposed to obtain integral structures with curved holes by combining traditional drilling and plastic forming processes. An analytical formula for cross-section distortion in BFCH was derived, taking into account the bending angle, billet thickness-to-hole diameter ratio, and material properties index. Experimental and simulation results confirmed the feasibility of the BFCH method, although oval-shaped distortion in the hole cross-sections was observed as the main defect. Appropriate initial temperature differences inside the billet can mitigate this distortion.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING
(2022)
Article
Engineering, Manufacturing
Xia Chen, Tong Wen, Jian Qin, Jin Hu, Meng Zhang, Zhi-sun Zhang
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING
(2020)