Study on cross-sectional deformation of rectangular waveguide tube with different materials in rotary draw bending
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terial mechanical behavior of tube has an essential influence on cross-sectional deformation of rectangular waveguide tube in rotary draw bending (RDB) process. Thus, taking widely used 3A21 aluminum alloy and H96 brass rectangular tubes as research objects, the cross-sectional deformation of these tubes in RDB with and without mandrel was investigated using the reliable three-dimensional finite element models. The results show that when no mandrel is used, compared with 3A21 tube, the position of wrinkle initiation for H96 tube is closer to the final bending section, and the cross-sectional deformation of H96 tube along bending direction is more homogeneous. When a mandrel is used, in bending process, the cross-sectional deformation of 3A21 tube in mandrel support zone (MSZ) is in coincidence with that of H96 tube, and the deformation of 3A21 tube is larger in transition zone (TZ) while smaller in no mandrel affect zone (NMAZ) than that of H96 tube. In retracting mandrel or springback process, the crosssectional deformation of 3A21 tube in MSZ and TZ is constantly larger than that of H96 tube, while in NMAZ, the deformation of both tubes reverses.
I. INTRODUCTION
The rectangular waveguide tubes have been extensively used in the fields of radar, satellite, electronic antagonism as well as space communication as a result of meeting the smooth dispersion characteristics, broad bandwidth and less signal loss.1,2 The rotary draw bending (RDB) process has become one of most common ways to bend tubes due to the merits of high precision, high efficiency, and cost-effective.3 However, owing to the structural features of thin-wall and hollowness for rectangular waveguide tube, the crosssectional deformation occurs inevitably in RDB process, which not only decreases the geometric accuracy, but also seriously influences the microwave transmission efficiency.4 When different waveguide materials are used, such as widely used 3A21 aluminum alloy and H96 brass, the mechanical behaviors of rectangular waveguide tube during RDB process will make a difference, which not only influences its stress/strain distribution characteristics in forming process but also determines its ability to resist the cross-sectional deformation. So exploring the crosssectional deformation behavior of rectangular waveguide tube with different materials in bending has become an important issue for further realizing tube material selection of rectangular waveguide and the improvement of product quality. Contributing Editor: Jürgen Eckert a) Address all correspondence to this author. e-mail: [email protected] DOI: 10.1557/jmr.2017.342
Over the years, a number of researches about the cross-sectional deformation of rectangular tube with different materials in bending process have been conducted through various methods. Paulsen and Welo5 experimentally investigated the cross-sectional deformation of aluminum alloy rectangular tube in pure bending and pointed out that distinct strain hardening characteristics obtained by different heat treatments have a large effect on t
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