Improvement On Rotary Draw Tube Bending's Parameter By Design And Analysis Using FEA Approach

Kee, Kuo Zhuan (2009) Improvement On Rotary Draw Tube Bending's Parameter By Design And Analysis Using FEA Approach. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This report represents a design & analysis case study on tube bending for metal forming industry. Where, tube bending is a widely used manufacturing process in the aerospace, automotive, and other industries. During tube bending, considerable in plane distortion and thickness variation occurs. The thickness increases at the intrados (surface of tube in contact with the die) and it reduces at the extrados (outer surface of the tube). The present project focuses on additional loadings such as axial force and internal pressure which can be used to achieve better shape control and strength of the tube. Based on plasticity theories, a FEA model is developed to predict displacement and stress of tubes under various loading conditions. Results from FEA model indicated that at the intrados the increase in thickness for bending with internal pressure and bending with combined axial pull and internal pressure was nearly the same. A parametric study was conducted for the case of bending with axial pull and it was seen that with proper selection of load and wrinkling defects can be eliminated, displacement the tube can be optimized, and fracture of the tube can be predicted. Predictions of model's results are in good agreement with finite element simulations. Thus, the proposed model can be used to evaluate tooling and process design in tube bending. Lastly, the prediction'S model of FEA can yield more precise dimensional of tube bending and quality of tube bending shall be increase into optimum level.

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