scholarly journals Springback angle prediction of circular metal tube considering the interference of cross-sectional distortion in mandrel-less rotary draw bending

2021 ◽  
Vol 104 (1) ◽  
pp. 003685042098430
Author(s):  
Huifang Zhou ◽  
Shuyou Zhang ◽  
Lemiao Qiu ◽  
Zili Wang
Keyword(s):  
Prediction Accuracy ◽  
Percentage Error ◽  
Al Alloy ◽  
Metal Tube ◽  
Rotary Draw Bending ◽  
Cross Sectional ◽  
The Cross ◽  
Draw Bending ◽  
Springback Prediction ◽  
Springback Angle

The springback directly affects the forming accuracy and quality of metal bent-tube, and accurate springback prediction is the key to the springback compensation and control. This paper investigates the springback of mandrel-less rotary draw bending (MLRDB) of circular metal tubes, and an innovative method, springback angle prediction considering the interference of cross-sectional distortion (IoCSD-SAP), is proposed. The digit decomposition condition variational auto-encoder generative adversarial network (D2CVAE-GAN) is developed to augment the data samples. Considering the nonlinear interference of the cross-sectional distortion on springback, auxiliary extended radial basis function (AE-RBF) is proposed. It establishes the mapping relationship between the characteristic parameters and cross-sectional distortion. By extracting the information encode of cross-sectional distortion as the condition input, this model realizes the condition prediction of springback angle. Taking MLRDB of 6060-T6 Al-alloy circular tube as a case study, the proposed method, IoCSD-SAP, is verified. According to the experimental results, the mean absolute percentage error (MAPE) for the springback angle of our proposed method is 4.73%, and three different analytical models are 38.92%, 14.39%, and 14.22%, respectively. It can be seen that our proposed method significantly improves the prediction accuracy of springback angle. For the springback angle prediction of circular metal tube in MLRDB, the data augmentation can effectively reduce the generalization error and improve the prediction accuracy. The nonlinear interference of the cross-sectional distortion on springback should be taken into account to improve the accuracy and robustness of the springback prediction model.

Development of Forming Method for Aluminum Alloy Channel with Curvature and Modified Cross-Section Shape in Rotary Draw Bending

2015 ◽  
Vol 1110 ◽  
pp. 130-135
Author(s):  
Kosuke Ito ◽  
Noah Utsumi ◽  
Masashi Yoshida
Keyword(s):  
Aluminum Alloy ◽  
Cross Sections ◽  
Manufacturing Systems ◽  
Bend Angle ◽  
Secondary Process ◽  
Rotary Draw Bending ◽  
Cross Sectional ◽  
Axial Tension ◽  
The Cross ◽  
Draw Bending

In the manufacturing industry, metal cross-sections and profiles are manufactured by using extrusion as the primary process. Subsequently, the products are generally subjected to bending in a secondary process. However, long products with the same cross-sections are typically mass-produced by one extrusion. In industries that manufacture such products, there have been increasing demands for flexible manufacturing systems that can be used for low-volume diverse products. However, it is difficult to adapt traditional manufacturing systems to this requirement. In this study, we aimed to develop a new bending method that can be used to deform the cross-sections of existing versatile extruded sections, such as channel materials and rectangular tubes, to several types of cross-sectional shapes and to simultaneously impose a desired curvature on them. The rotary draw bending process for an aluminum alloy channel material without tensile flanges was investigated by using the finite element method and experiments. The effects of the bend angle and thickness ratio on the cross-sectional deformation were examined. Furthermore, the influence of additional axial tension on the channel materials was studied. Additional axial tension can be used to control the outward and inward deformations of the webs. In addition, it was confirmed that the axial tension is very effective in preventing wrinkling and folding.

A New Method to Accurately Describe Cross-Section Distortion in Rotary Draw Bending Process of Thin-Walled Rectangular Tube

2011 ◽  
Vol 117-119 ◽  
pp. 1839-1842
Author(s):  
Gang Yao Zhao ◽  
Rang Yang Zhang ◽  
Yu Li Liu ◽  
Zheng Hua Guo ◽  
Ping Fang
Keyword(s):  
Current Model ◽  
New Method ◽  
Rotary Draw Bending ◽  
Cross Sectional ◽  
Bending Process ◽  
Rectangular Tube ◽  
Side Walls ◽  
Thin Walled ◽  
The Cross ◽  
Draw Bending

To obtain the cross-sectional distortion of thin-walled rectangular tube in rotary draw bending process accurately, a new method to exactly describe the distortion has been proposed. The coupling between the convex of the tube side walls and the concave of the tube flanges is considered in the distortion modeling. Combined with the experiments, the cross-sectional distortion obtained using the new distortion model are compared with the previous ones obtained without considering the convex based on numerical simulations. The results show that cross-sectional distortion obtained by current model is closer to reality than the previous ones. The distortion by current model is more safety in the practical bending process.

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