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<p>Corner cracking in square and rectangular tubes during the cold bending forming process poses a significant technical challenge. This research aims to clarify the underlying causes of corner cracking through experimental investigations and numerical simulations while also proposing viable solutions. Tensile tests were conducted on the MS1180 material to calibrate the material parameters, and the Oyane fracture criterion was employed to enhance the precision of crack prediction. A finite element model was developed using Marc software to simulate the cold bending forming process. This model enables an analysis of how the reduction ratio, number of passes, and tube wall thickness affect the stress and strain distribution at the corners of tubes. The results indicate that modifying the reduction ratio, increasing the number of passes, and reducing the tube wall thickness can significantly reduce cracking issues. These findings provide a theoretical framework for addressing the challenges of corner cracking in square and rectangular tubes.</p>

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Research on the cracking at the corner of MS1180 square tube during cold roll forming based on the Oyane fracture criterion

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • Guangxuan Wang,
  • Xiaoli Liu,
  • Suxia Huang,
  • Hezong Li,
  • Ning Kong,
  • Haiqiang Wen,
  • Juzheng Feng,
  • Yucheng Mao,
  • Yinuo Ma,
  • Hongshun Zhang

摘要

Corner cracking in square and rectangular tubes during the cold bending forming process poses a significant technical challenge. This research aims to clarify the underlying causes of corner cracking through experimental investigations and numerical simulations while also proposing viable solutions. Tensile tests were conducted on the MS1180 material to calibrate the material parameters, and the Oyane fracture criterion was employed to enhance the precision of crack prediction. A finite element model was developed using Marc software to simulate the cold bending forming process. This model enables an analysis of how the reduction ratio, number of passes, and tube wall thickness affect the stress and strain distribution at the corners of tubes. The results indicate that modifying the reduction ratio, increasing the number of passes, and reducing the tube wall thickness can significantly reduce cracking issues. These findings provide a theoretical framework for addressing the challenges of corner cracking in square and rectangular tubes.