A Study on Multi-defect Constrained Bendability of Thin-walled Tube NC Bending Under Different Clearance

Abstract Thin-walled tube numerical control (NC) bending is a tri-nonlinear physical process with multi-defect and multi-die constraints. The clearance on each contact interface is the major factor to indicate the contact conditions. A three-dimensional-finite element (3D-FE) model is established to consider the realistic dynamic boundary conditions of multiple dies under ABAQUS/Explicit platform. Combined with experiment, numerical study on bending behavior and bendability under different clearance between tube and various dies is conducted in terms of wrinkling, wall thinning and cross section deformation. The results show that (1)with smaller clearance of tube-wiper die and tube-mandrel, the wrinkling can be restrained while the wall thinning It and cross-section deformation Id increase; while excessive small clearance blocks tube materials to flow past tangent point and causes piles up, the onset of wrinkling enhances It and Id. (2)Both It and Id decrease with smaller clearance of tube-pressure die; the wrinkling possibility rises with larger clearance on this interface if the mandrel's freedom along Y-axis is opened; smaller clearance of tube-bend die prevents wrinkling while increases It, and the clearance on this interface has little effect on Id. (3)A modified Yoshida buckling test (YBT) is used to address the wrinkling mechanisms under normal constraints in tube bending: the smaller clearance may restrain wrinkling efficiently; the smaller wall thickness, the less critical clearance needed; the critical clearance for tube bending 38 mm×1 mm×57 mm (tube outer diameter×wall thickness×centerline bending radius) equals about 20% of initial wall thickness.