Influences on the extended length and performance of push bending for the GH4169 superalloy tube with small bending radi
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ORIGINAL ARTICLE
Influences on the extended length and performance of push bending for the GH4169 superalloy tube with small bending radius of 1D Jie Xiao 1,2 & Xuefeng Xu 2 & Dunwen Zuo 1 & Yubin Fan 3 & Kongwei Wu 3 Received: 6 February 2020 / Accepted: 19 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract It is extremely difficult to eliminate the defects like wrinkling, which is generated in the bending of tube with small bending radius. In this thesis, the push-bending process of the GH4169 superalloy tube with a large diameter-thickness ratio of 60 and small bending radius of 1D is studied by numerical simulations and experiments, aiming to eliminate wrinkles on the inside of the tube and obtain enough extended length (e) of straight segment as well as minimal changes in the wall thickness. Three influencing factors, such as the inclined angle (α) at the initial end, the reverse thrust (P) of polyurethane blocks, and the lubrication, are investigated in the simulation. According to the simulations, the proposed experiment is successfully implemented on an independent development of push-bending equipment. The results are in good agreement with the simulation. The optimum parameters for the GH4169 superalloy alloy tube with a large diameter-thickness ratio of 60 and small bending radius of 1D are simulated. And then α is optimized to 45° and P is optimized to 48 MPa. And differential lubrication is used for longer extended length of straight segment and more uniform distribution of wall thickness on both sides of the deformed elbow. Keywords GH4169 superalloy . Push bending . Wrinkle . Extended length of straight segment . Wall thickness distribution
1 Introduction To satisfy the requirements of weight lightening, space saving, and integral forming, thin-walled tubes with relatively small bending radius are often used in aerospace industry. At present, the bending process mainly includes rotary draw bending [1–4], roll bending [5, 6], hydro-bulging bending [7, 8], and push bending [9–11]. A great many of studies have been exploring in different tube bending processes of various tubular materials. Yang He et al. [12] studied a rotary draw bending of a thinwalled aluminum alloy with the bending radius of 1.5D and
* Xuefeng Xu [email protected] 1
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2
National Defence Key Discipline Laboratory of Light Alloy Processing Science and Technology, Nanchang Hangkong University, Nanchang 330063, China
3
School of Aeronautical Manufacturing Engineering, Nanchang Hangkong University, Nanchang 330063, China
the diameter of 50 mm, and then proved the method of numerical control warm bending to form the large diameter of thin-walled Ti-6Al-4V tubes. The bending radius was 2D [13]. Tabakajew et al. [14, 15] presented a warm forming process of hot mandrel bending of pipe elbows, which was so-called the Hamburg process. The end of tube was heated by an inductor and then
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