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<p>To solve the problems of thickening and wrinkling on the inside of aluminum alloy small bend radius tube bends, insufficient length of output section, and cracking of output section ports, this paper takes a 5A02 aluminum alloy thin-walled tube with a relative bending radius of 0.9, an outer diameter of 32&#xa0;mm, and a wall thickness of 1&#xa0;mm as the research object. This is the first study to propose a new process and a new device for push–pull-rotate–integrated (P-P-RI) bending forming. A finite element model was established, and the P-P-RI bending forming experiment was carried out. The study shows that the intervention of the tension load can effectively reduce the gap between the polyurethane blocks, so that the bending tube in the forming process has more uniform force. When the tension load is 360&#xa0;MPa, under the premise of ensuring that the length of the output section is sufficient, it can also effectively improve the degree of bending tube cross-sectional distortion. The rotational speed of the rotating wheel has an important impact on the length of the output section of the bend; the greater the speed of rotation, the longer the length of the output section of the bend. Lubrication of the inside and outside of the tube bends using “large inside, small outside” sub-area differentiation can effectively improve the inner side of the tube bends’ thickening wrinkles and the output section of the port by reducing the thinning phenomenon of cracking.</p>

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Numerical simulation and experimental study on push–pull-rotate–integrated bending forming of 5A02 aluminum alloy

  • 期刊论文

  • 发表日期：

    2025年4月12日

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  • Jiesong Liu,
  • Xuefeng Xu,
  • Mingliang Peng,
  • Jun Xie,
  • Yubin Fan,
  • Jie Liu

摘要

To solve the problems of thickening and wrinkling on the inside of aluminum alloy small bend radius tube bends, insufficient length of output section, and cracking of output section ports, this paper takes a 5A02 aluminum alloy thin-walled tube with a relative bending radius of 0.9, an outer diameter of 32 mm, and a wall thickness of 1 mm as the research object. This is the first study to propose a new process and a new device for push–pull-rotate–integrated (P-P-RI) bending forming. A finite element model was established, and the P-P-RI bending forming experiment was carried out. The study shows that the intervention of the tension load can effectively reduce the gap between the polyurethane blocks, so that the bending tube in the forming process has more uniform force. When the tension load is 360 MPa, under the premise of ensuring that the length of the output section is sufficient, it can also effectively improve the degree of bending tube cross-sectional distortion. The rotational speed of the rotating wheel has an important impact on the length of the output section of the bend; the greater the speed of rotation, the longer the length of the output section of the bend. Lubrication of the inside and outside of the tube bends using “large inside, small outside” sub-area differentiation can effectively improve the inner side of the tube bends’ thickening wrinkles and the output section of the port by reducing the thinning phenomenon of cracking.