On the Three-Dimensional Laser Bending of Metal Tubes

2012 ◽  
Vol 197 ◽  
pp. 297-301
Author(s):  
Nan Hai Hao ◽  
Yu Ling Gai

Laser tube bending is a kind of plastic forming method with high flexibility, and is suitable for the low ductility material and thin thickness tube. This paper proposes a systematic scheme for three-dimensional tube bending, which forms the tube by varying the bending position and bending direction continuously. The bending part is simplified as a three-dimensional curve and then the curve is divided into segments and substituted with line sections. The scheme takes the angle between two adjacent segments as the laser bending angle at each bending position and the angle between two adjacent bending plane as the variation of bending direction. The effectiveness of proposed scheme is verified with the forming of a helical tube experimentally. The dimension errors of the formed helical tube are 6.25% in diameter and 7.59% in pitch respectively.

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1123
Author(s):  
Mehdi Safari ◽  
Ricardo J. Alves de Sousa ◽  
Jalal Joudaki

The laser tube bending process (LTBP) process is a thermal non-contact process for bending tubes with less springback and less thinning of the tube. In this paper, the laser tube bending process will be studied experimentally. The length of irradiation and irradiation scheme are two main affecting process parameters in the LTBP process. For this purpose, different samples according to two main irradiation schemes (Circular irradiating scheme (CIS) and axial irradiating scheme (AIS)) and different lengths of laser beam irradiation (from 4.7 to 28.2 mm) are fabricated. The main bending angle of laser-bent tube, lateral bending angle, ovality, and thickness variations is measured experimentally, and the effects of the irradiating scheme and the length of irradiation are investigated. An 18 mm diameter, 1 mm thick mild steel tube was bent with 1100 Watts laser beam. The results show that for both irradiating schemes, by increasing the irradiating length of the main and lateral bending angle, the ovality and thickness variation ratio of the bent tube are increased. In addition, for a similar irradiating length, the main bending angle with AIS is considerably higher than CIS. The lateral bending angle by AIS is much less than the lateral bending angle with CIS. The results demonstrate that the ovality percentage and the thickness variation ratio for the laser-bent tube obtained by CIS are much more than the values associated with by AIS laser-bent tube.


2006 ◽  
Vol 129 (3) ◽  
pp. 592-600 ◽  
Author(s):  
Shakeel Safdar ◽  
Lin Li ◽  
M. A. Sheikh ◽  
Zhu Liu

Laser forming is a spring-back-free noncontact forming method that has received considerable attention in recent years. Compared to mechanical bending, no hard tooling, dies, or external force is used. Within laser forming, tube bending is an important industrial activity with applications in critical engineering systems such as heat exchangers, hydraulic systems, boilers, etc. Laser tube bending utilizes the thermal stresses generated during laser scanning to achieve the desired bends. The parameters varied to control the process are usually laser power, beam diameter, scanning velocity, and the number of scans. The thermal stresses generated during laser scanning are strongly dependent upon laser beam geometry. The existing laser bending methods use either circular or rectangular beams. These beam geometries sometimes lead to undesirable effects such as buckling and distortion in tube bending. This paper investigates the effects for various laser beam geometries on laser tube bending. Finite element modeling has been used for the study of the process with some results also validated by experiments.


2012 ◽  
Vol 184-185 ◽  
pp. 505-509
Author(s):  
Heng Li ◽  
He Yang ◽  
Kai Peng Shi

Strain distribution is crucial for understanding tube bending and preventing defects. In this paper, taking 321 stainless steel as the objective, via etched grid method, the strain distribution characteristics during tube bending are studied, the effects of the bending velocity and the bending angle on the strain distribution are analyzed, and the consistency of thickness strain with wall thickness variation is verified. The results show that: (1) three-dimensional (3D) strain is symmetrically distributed about bending plane and reaches the maximum value at wall extrados and intrados; (2) absolute value of the 3D strain increases at first, then decreases in tube bending; (3) compared with bending angle, bending velocity has greater effect on spatial strain, and compared with tangent strain, thickness strain is more sensitive to bending velocity; (4) thickness strain distribution characteristics are generally consistent with distribution characteristics of wall thinning degree.


Author(s):  
Frank Wagner ◽  
Arnold Kühhorn ◽  
Thomas Weiss ◽  
Dierk Otto

Today the design processes in the aero industry face many challenges. Apart from automation itself, a suitable parametric geometry setup plays a significant role in making workflows usable for optimization. At the same time there are tough requirements against the parametric model. For the lowest number of possible parameters, which should be intuitively ascertainable, a high flexibility has to be ensured. Within the parameter range an acceptable stability is necessary. Under these constraints the creation of such parametric models is a challenge, which should not be underestimated especially for a complex geometry. In this work different kinds of parametrization with different levels of complexity will be introduced and compared. Thereby several geometry elements will be used to handle the critical regions of the geometry. In the simplest case a combination of lines and arcs will be applied. These will be replaced by superior elements like a double arc construct or different formulations of b-splines. There will be an additional focus on the variation of spline degree and control points. To guarantee consistency a set of general parameters will be used next to the specific ones at the critical regions. The different parameter boundaries have a influence on the possible geometries and should therefore be tested separately before an optimization run. The analysis of the particular parametrization should be compared against the following points: • effort for the creation of the parametrization in theory • required time for the implementation in the CAD software • error-proneness/robustness of the parametrization • flexibility of the possible geometries • accuracy of the results • influence of the number of runs on the optimization • comparison of the best results Even though this assessment matrix is only valid for the considered case, it should show the general trend for the creation of these kinds of parametric models. This case takes a look at a firtree of a high pressure turbine blade, which is a scaled version of the first row from a small to medium aero engine. The failure of such a component can lead to a critical engine failure. For that reason, the modeling/meshing must be done very carefully and the contact between the blade and the disc is of crucial importance. It is possible to use scaling factors for three dimensional effects to reduce the problem to a two dimensional problem. Therefore the contact description is shortened from face-to-line to line-to-point. The main aim of the optimization is the minimization of the tension (notch stress) at the inner bends of the blade respectively at the outer bends of the disc. This has been the limiting factor in previous investigations. At this part of the geometry the biggest improvement are expected from a superior parametrization. Another important constraint in the optimization is the pressure contact (crushing stress) between blade and disc. Additionally the geometry is restricted with measurements of the lowest diameter at specific fillets to fulfill manufacturing requirements.


Author(s):  
Bisheng Yang ◽  
Yuan Liu ◽  
Fuxun Liang ◽  
Zhen Dong

High Accuracy Driving Maps (HADMs) are the core component of Intelligent Drive Assistant Systems (IDAS), which can effectively reduce the traffic accidents due to human error and provide more comfortable driving experiences. Vehicle-based mobile laser scanning (MLS) systems provide an efficient solution to rapidly capture three-dimensional (3D) point clouds of road environments with high flexibility and precision. This paper proposes a novel method to extract road features (e.g., road surfaces, road boundaries, road markings, buildings, guardrails, street lamps, traffic signs, roadside-trees, power lines, vehicles and so on) for HADMs in highway environment. Quantitative evaluations show that the proposed algorithm attains an average precision and recall in terms of 90.6% and 91.2% in extracting road features. Results demonstrate the efficiencies and feasibilities of the proposed method for extraction of road features for HADMs.


2015 ◽  
Vol 782 ◽  
pp. 300-332 ◽  
Author(s):  
Fangfang Xie ◽  
Yue Yu ◽  
Yiannis Constantinides ◽  
Michael S. Triantafyllou ◽  
George Em Karniadakis

We employ three-dimensional direct and large-eddy numerical simulations of the vibrations and flow past cylinders fitted with free-to-rotate U-shaped fairings placed in a cross-flow at Reynolds number $100\leqslant \mathit{Re}\leqslant 10\,000$. Such fairings are nearly neutrally buoyant devices fitted along the axis of long circular risers to suppress vortex-induced vibrations (VIVs). We consider three different geometric configurations: a homogeneous fairing, and two configurations (denoted A and AB) involving a gap between adjacent segments. For the latter two cases, we investigate the effect of the gap on the hydrodynamic force coefficients and the translational and rotational motions of the system. For all configurations, as the Reynolds number increases beyond 500, both the lift and drag coefficients decrease. Compared to a plain cylinder, a homogeneous fairing system (no gaps) can help reduce the drag force coefficient by 15 % for reduced velocity $U^{\ast }=4.65$, while a type A gap system can reduce the drag force coefficient by almost 50 % for reduced velocity $U^{\ast }=3.5,4.65,6$, and, correspondingly, the vibration response of the combined system, as well as the fairing rotation amplitude, are substantially reduced. For a homogeneous fairing, the cross-flow amplitude is reduced by about 80 %, whereas for fairings with a gap longer than half a cylinder diameter, VIVs are completely eliminated, resulting in additional reduction in the drag coefficient. We have related such VIV suppression or elimination to the features of the wake flow structure. We find that a gap causes the generation of strong streamwise vorticity in the gap region that interferes destructively with the vorticity generated by the fairings, hence disorganizing the formation of coherent spanwise cortical patterns. We provide visualization of the incoherent wake flow that leads to total elimination of the vibration and rotation of the fairing–cylinder system. Finally, we investigate the effect of the friction coefficient between cylinder and fairing. The effect overall is small, even when the friction coefficients of adjacent segments are different. In some cases the equilibrium positions of the fairings are rotated by a small angle on either side of the centreline, in a symmetry-breaking bifurcation, which depends strongly on Reynolds number.


2021 ◽  
Vol 136 ◽  
pp. 106755
Author(s):  
Yongjun Shi ◽  
Yankuo Guo ◽  
Xiaogang Wang ◽  
Rui Sun ◽  
Xianfa Li

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 370 ◽  
Author(s):  
Jianing Li ◽  
Huaping Wang ◽  
Juan Cui ◽  
Qing Shi ◽  
Zhiqiang Zheng ◽  
...  

Magnetic micromachines as wireless end-effectors have been widely applied for drug discovery and regenerative medicine. Yet, the magnetic assembly of arbitrarily shaped cellular microstructures with high efficiency and flexibility still remains a big challenge. Here, a novel clamp-shape micromachine using magnetic nanoparticles was developed for the indirect untethered bioassembly. With a multi-layer template, the nickel nanoparticles were mixed with polydimethylsiloxane (PDMS) for mold replication of the micromachine with a high-resolution and permeability. To actuate the micromachine with a high flexibility and large scalable operation range, a multi-pole electromagnetic system was set up to generate a three-dimensional magnetic field in a large workspace. Through designing a series of flexible translations and rotations with a velocity of 15mm/s and 3 Hz, the micromachine realized the propel-and-throw strategy to overcome the inevitable adhesion during bioassembly. The hydrogel microstructures loaded with different types of cells or the bioactive materials were effectively assembled into microtissues with reconfigurable shape and composition. The results indicate that indirect magnetic manipulation can perform an efficient and versatile bioassembly of cellular micromodules, which is promising for drug trials and modular tissue engineering.


2010 ◽  
Vol 431-432 ◽  
pp. 118-121
Author(s):  
Peng Zhang ◽  
Hong Wei Liu

Laser bending process of sheet metals is a highly flexible forming technique. Simulate model of laser bending process was established by dimension analysis, and the control model of laser bending was achieved with the regression of swatch datum. It was shown that dimension analysis was an effective method in simulating the complex laser bending process, and the control model, which came from non-dimension group datum, was a high-accuracy model in predictive analysis of bending angle.


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