During stretch bending, considerable springback will occur after a tube has been plastically bent. To predict the springback, a simplified two-flange model for stretch bending of a rectangular tube has been developed in which the strain history has been considered. A comparison has been made between the springback predicted by this model and experimental data, which shows rough agreement. Based on this model, a real time closed-loop control algorithm is developed.
Issue Section:
Technical Papers
Keywords:
bending,
mechanical variables control,
closed loop systems,
plastic deformation,
manufacturing processes
Topics:
Aluminum,
Control algorithms,
Deformation,
Flanges,
Modeling,
Stress,
Tension,
Surface roughness,
Errors
1.
Zhu
, H.
, and Stelson
, K. A.
, 2002
, “Distortion of Rectangular Tubes in Stretch Bending
,” ASME J. Manuf. Sci. Eng.
, 124
, pp. 886
–890
.2.
Miller
, J. E.
, Kyriakides
, S.
, and Corona
, E.
, 2001
, “On Bend-stretch Forming of Aluminum Extruded Tubes—II: Analysis
,” Int. J. Mech. Sci.
, 43
, pp. 1319
–1338
.3.
El-Domiaty
, A. A.
, and Shabaik
, A. H.
, 1984
, “Bending of Work-hardening Metals under the Influence of Axial Load
,” J. Mech. Work. Technol.
, 10
, pp. 57
–66
.4.
El-Megharbel
, A.
, El-Domiaty
, A.
, and Shaker
, M.
, 1990
, “Springback and Residual Stresses after Stretch Bending of Work-hardening Sheet Metal
,” J. Mater. Process. Technol.
, 24
, pp. 191
–200
.5.
El-Domiaty
, A. A.
, 1990
, “Stretch Forming of Beams of Nonuniform Section
,” J. Mater. Process. Technol.
, 22
, pp. 21
–28
.6.
El-Domiaty
, A. A.
, Shabara
, M. A.
, and Al-Ansary
, M. D.
, 1996
, “Determination of Stretch-Bendability of Sheet Metals
,” Int. J. Mach. Tools Manuf.
, 36
(5
), pp. 635
–650
.7.
El-Domiaty
, A. A.
, and Elsharkawy
, A. A.
, 1998
, “Stretch Bending Analysis of U-Section Beams
,” Int. J. Mach. Tools Manuf.
, 38
(1–2
), pp. 75
–95
.8.
Elsharkawy
, A. A.
, and El-Domiaty
, A. A.
, 2001
, “Determination of Stretch-bendability Limits and Springback for T-section Beams
,” J. Mater. Process. Technol.
, 110
, pp. 265
–276
.9.
Ueda
, M.
, and Ueno
, K.
, 1981
, “A Study of Springback in the Stretch Bending of Channels
,” J. Mech. Work. Technol.
, 5
, pp. 163
–179
.10.
Kuwabara
, T.
, Takahashi
, S.
, Akiyama
, K.
, and Miyashita
, Y.
, 1995
, “2-D Springback Analysis for Stretch Bending Processes Based on Total Strain Theory
,” Automotive Stamping Technology
,Sp-1067
, 950691
950691
.11.
Parris, A., 1996, “Precision Stretch Forming of Metal for Precision Assembly,” Ph.D. thesis, Massachusetts Institute of Technology, 1996.
12.
Hunter, D. E., and Pourboghrat, F., 1993, “Elastic Recovery in Extrusion Bending—Predicting Die Contour to Produce Net Shape Parts Using FEM,” Processing of the Near Net Shape Manufacturing Conference, Pittsburgh, PA, September.
13.
Geiger
, M.
, and Sprenger
, A.
, 1998
, “Controlled Bending of Aluminum Extrusions
,” CIRP Ann.
, 47
(1
), pp. 197
–202
.14.
Clausen
, A. H.
, Hopperstad
, O. S.
, and Langseth
, M.
, 1999, “Stretch Bending of Aluminum Extrusions: Effect of Geometry and Alloy,” J. Eng. Mech., April, pp. 392–400.15.
Clausen
, A. H.
, Hopperstad
, O. S.
, and Langseth
, M.
, 1999, “Stretch Bending of Aluminum Extrusions: Effect of Tensile Sequence,” J. Eng. Mech., May, pp. 521–529.16.
Clausen
, A. H.
, Hopperstad
, O. S.
, and Langseth
, M.
, 2000
, “Stretch Bending of Aluminum Extrusion for Car Bumpers
,” J. Mater. Process. Technol.
, 102
, pp. 241
–248
.17.
Clausen
, A. H.
, Hopperstad
, O. S.
, and Langseth
, M.
, 2001
, “Sensitivity of Model Parameters in Stretch Bending of Aluminum Extrusions
,” Int. J. Mech. Sci.
, 43
, pp. 427
–453
.18.
Miller
, J. E.
, Kyriakides
, S.
, and Bastard
, A. H.
, 2001
, “On Bend-stretch Forming of Aluminum Extruded Tubes—I: Experiments
,” Int. J. Mech. Sci.
, 43
, pp. 1283
–1317
.19.
Stelson
, K. A.
, and Gossard
, D. C.
, 1982
, “An Adaptive Pressbrake Control Using an Elastic-Plastic Material Model
,” ASME J. Ind.
, 104
, pp. 389
–393
.20.
Stelson
, K. A.
, 1983
, “Real Time Identification of Workpiece Material Characteristics from Measurements During Brake Forming
,” ASME J. Ind.
, 105
, pp. 45
–53
.21.
Voce
, E.
, 1948
, “The Relationship Between Stress and Strain for Homogeneous Deformation
,” J. Inst. Met.
, 74
, pp. 537
–562
.22.
Paulsen
, F.
, and Welo
, T.
, 1996
, “Application of Numerical Simulation in the Bending of Aluminum-Alloy Profiles
,” J. Mater. Process. Technol.
, 58
, pp. 274
–285
.Copyright © 2003
by ASME
You do not currently have access to this content.