The effect of frictions between dies and tube on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical analysis and experi...The effect of frictions between dies and tube on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical analysis and experiment. The results show that the frictions between mandrel, wiper, pressure die, bending die and tube have a significant and complicate effect on the section quality of thin-walled tube NC bending. To improve the section quality, frictions between mandrel, wiper and tube should be decreased, but the frictions between the pressure die, bending die and tube increase. The effect on the section distortion is more significant from mandrel, wiper, pressure die to bending die and the effect on the wall thinning more significant from mandrel, pressure die, wiper, to bending die. The effects of frictions between all dies and tube on wall thinning are smaller than their effects on section distortion. Mandrel and wiper should be lubricated well and drawing oil is used to lubricate them in actual production. The frictions between pressure die, bending die and tube should be increased and the dry friction is used between pressure die, bending die and tube in actual production.展开更多
The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (anal...The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (analysis) and experiment. Influencing factors of the mandrel include the count of mandrel heads, the diameter of mandrel and its position. According to the principle of NC tube bending, quality defects possibly produced in thin-walled tube NC bending process were analyzed and two parameters were proposed in order to describe the cross section quality of thin-walled tube NC bending. According to the geometrical dimension of tube and dies, the range of mandrel protrusion was derived. The finite element model of thin-walled tube NC bending was established based on the DYNAFORM platform, and key technological problems were solved. The model was verified by experiment. The effect of the number of mandrel heads, the diameter of mandrel and the protrusion length of mandrel on the cross section quality of thin-walled tube NC bending was revealed and how to choose mandrel parameters was presented.展开更多
In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis meth...In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis method and the springback/section deformation prediction finite element model, and by using this model the sensitivities of the springback and the section deformation to process parameters were analyzed and compared. The results show that the most sensitive process conditions for springback angle are the boost speed and the pressure of pressure die, and the most sensitive process condition for section deformation is the number of cores. When the clamp force, the boost speed and the pressure of pressure die are utilized to control section deformation, the effect of these process parameters on springback should be considered. When the process parameters are mainly used to control springback, the effect of these process parameters on the section deformation should be always considered.展开更多
Cross-section deformation is one of important factors affecting the quality of tube formation, and the tube＇s capability of transporting liquid and gas will be reduced because of the cross-section ellipse deformation...Cross-section deformation is one of important factors affecting the quality of tube formation, and the tube＇s capability of transporting liquid and gas will be reduced because of the cross-section ellipse deformation due to the effect of shear load in plastic bending process. When the tube is bent, the extrados-wall bears the tension stress and the intrados-wall bears the compression stress, synchronously the cross-section is affected by the circumferential stress. According to the above, the distribution function and curve of tangential stress can be obtained according to force balance differential equations on circumferential direction and Trasca rule. Subsequently the real state and virtual state moment equations were established, a new method was presented adopting the virtual principle of deformation system to calculate the x-axis and y-axis displacement of arbitrary point on cross-section. So the major and minor axes of deformed cross-section can be calculated according to the displacements of each point, and the variety value of major and minor axes will be obtained further. Finally the theoretical calculating result is compared with NC tube rotary-bending experiment results to verify the rationality of theoretical analysis, and the cross-section deformation rule of thin-walled tube can be received.展开更多
Based on the theories of Bernoulli-Euler beams and Vlasov's thin-walled members,a new geometrical and physical nonlinear beam element model is developed by applying an interior node in the element and independent ...Based on the theories of Bernoulli-Euler beams and Vlasov's thin-walled members,a new geometrical and physical nonlinear beam element model is developed by applying an interior node in the element and independent interpolations on bending angles and warp,in which factors such as traverse shear deformation,torsional shear deformation and their coupling,coupling of flexure and torsion,and second shear stress are all considered.Thereafter,geometrical nonlinear strain in total Lagarange(TL) and the corresponding stiffness matrix are formulated.Ideal plastic model is applied to physical nonlinearity to comply with the yield rule of Von Mises and incremental relationship of Prandtle-Reuss.Elastoplastic stiffness matrix is derived by numerical integration on the basis of the finite segment method.Examples show that the developed model is feasible in analysis of thin-walled structures with high accuracy.展开更多
基金Project(50225518) supported by the National Science Foundation of China for Distinguished Young Scholars Projects(50175092+4 种基金 59975076) supported by the National Natural Science Foundation of China Project supported by the Teaching and Research Award Program for Outstanding Young Teachers in Higher Education Institutions of MOE, China Project(04H53057) supported by the Aeronautical Science Foundation of China Project(20020699002) supported by the Specialized Research Fund for the Doctoral Program of Higher Education, China Project(Z200518) supported by the Graduate Starting Seed Fund of Northwestern Polytechnical University, China
文摘The effect of frictions between dies and tube on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical analysis and experiment. The results show that the frictions between mandrel, wiper, pressure die, bending die and tube have a significant and complicate effect on the section quality of thin-walled tube NC bending. To improve the section quality, frictions between mandrel, wiper and tube should be decreased, but the frictions between the pressure die, bending die and tube increase. The effect on the section distortion is more significant from mandrel, wiper, pressure die to bending die and the effect on the wall thinning more significant from mandrel, pressure die, wiper, to bending die. The effects of frictions between all dies and tube on wall thinning are smaller than their effects on section distortion. Mandrel and wiper should be lubricated well and drawing oil is used to lubricate them in actual production. The frictions between pressure die, bending die and tube should be increased and the dry friction is used between pressure die, bending die and tube in actual production.
文摘The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled(NC) bending was studied by numerical simulation method, combined with theoretical (analysis) and experiment. Influencing factors of the mandrel include the count of mandrel heads, the diameter of mandrel and its position. According to the principle of NC tube bending, quality defects possibly produced in thin-walled tube NC bending process were analyzed and two parameters were proposed in order to describe the cross section quality of thin-walled tube NC bending. According to the geometrical dimension of tube and dies, the range of mandrel protrusion was derived. The finite element model of thin-walled tube NC bending was established based on the DYNAFORM platform, and key technological problems were solved. The model was verified by experiment. The effect of the number of mandrel heads, the diameter of mandrel and the protrusion length of mandrel on the cross section quality of thin-walled tube NC bending was revealed and how to choose mandrel parameters was presented.
基金Project (50975235) supported by the National Natural Science Foundation of ChinaProject (B08040) supported by the 111 Project
文摘In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis method and the springback/section deformation prediction finite element model, and by using this model the sensitivities of the springback and the section deformation to process parameters were analyzed and compared. The results show that the most sensitive process conditions for springback angle are the boost speed and the pressure of pressure die, and the most sensitive process condition for section deformation is the number of cores. When the clamp force, the boost speed and the pressure of pressure die are utilized to control section deformation, the effect of these process parameters on springback should be considered. When the process parameters are mainly used to control springback, the effect of these process parameters on the section deformation should be always considered.
基金supported by "Eleven Five Years Plan" Basic Research Item of National Defense of China (Grant No. B2220060048)
文摘Cross-section deformation is one of important factors affecting the quality of tube formation, and the tube＇s capability of transporting liquid and gas will be reduced because of the cross-section ellipse deformation due to the effect of shear load in plastic bending process. When the tube is bent, the extrados-wall bears the tension stress and the intrados-wall bears the compression stress, synchronously the cross-section is affected by the circumferential stress. According to the above, the distribution function and curve of tangential stress can be obtained according to force balance differential equations on circumferential direction and Trasca rule. Subsequently the real state and virtual state moment equations were established, a new method was presented adopting the virtual principle of deformation system to calculate the x-axis and y-axis displacement of arbitrary point on cross-section. So the major and minor axes of deformed cross-section can be calculated according to the displacements of each point, and the variety value of major and minor axes will be obtained further. Finally the theoretical calculating result is compared with NC tube rotary-bending experiment results to verify the rationality of theoretical analysis, and the cross-section deformation rule of thin-walled tube can be received.
基金supported by the National Natural Science Foundation of China(Grant No.50725826)
文摘Based on the theories of Bernoulli-Euler beams and Vlasov's thin-walled members,a new geometrical and physical nonlinear beam element model is developed by applying an interior node in the element and independent interpolations on bending angles and warp,in which factors such as traverse shear deformation,torsional shear deformation and their coupling,coupling of flexure and torsion,and second shear stress are all considered.Thereafter,geometrical nonlinear strain in total Lagarange(TL) and the corresponding stiffness matrix are formulated.Ideal plastic model is applied to physical nonlinearity to comply with the yield rule of Von Mises and incremental relationship of Prandtle-Reuss.Elastoplastic stiffness matrix is derived by numerical integration on the basis of the finite segment method.Examples show that the developed model is feasible in analysis of thin-walled structures with high accuracy.
