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<p>Thin-walled polygonal tubes, particularly seamless square profiles, are widely used in heat exchange and energy transport due to their favorable strength-to-weight ratio and assembly efficiency. However, conventional manufacturing routes remain costly and inflexible, and the deformation mechanisms in incremental tube forming (ITF)—especially thinning and springback in the XY and XZ planes during circular-to-square transformation—are not yet well quantified. This study investigates these mechanisms through full-factorial ITF experiments on thin-walled copper tubes using a three-axis CNC machine with a ball-tip tool over a 16&#xa0;mm forming length, supported by explicit LS-DYNA shell simulations and quadratic response surface modelling. Numerical predictions show strong agreement with experimental measurements of both responses, with thickness prediction errors (MAPE) in the range of 4–5% and springback prediction errors below 3%, respectively, along with corresponding mean absolute error (MAE) values. Statistical analysis reveals a clear hierarchy of process influence: maximum thinning is governed primarily by axial feed, whereas springback exhibits nonlinear multivariate behavior dominated by radial feed, followed by axial feed and tool velocity, with significant interaction effects. The quadratic models, highly predictive for springback and sufficiently accurate for thinning, enable desirability-based multi-objective optimization, identifying 650&#xa0;mm/min velocity, 0.35&#xa0;mm axial feed, and 0.25&#xa0;mm radial feed as an optimal operating condition. This parameter set limits thinning to approximately 0.45, reduces springback in both planes to 0.69 and 0.60, and achieves an overall desirability of nearly 0.7, thereby establishing a validated process window for defect-sensitive ITF of square tubes.</p>

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Experimental and numerical evaluation of process parameters influencing thinning and springback in incremental squaring of thin-walled copper tubes

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Moataz Abd El Kafy,
  • Mostafa Shazly,
  • Gamal Abd El Nasser,
  • Eslam Shamso,
  • Noha Naeim

摘要

Thin-walled polygonal tubes, particularly seamless square profiles, are widely used in heat exchange and energy transport due to their favorable strength-to-weight ratio and assembly efficiency. However, conventional manufacturing routes remain costly and inflexible, and the deformation mechanisms in incremental tube forming (ITF)—especially thinning and springback in the XY and XZ planes during circular-to-square transformation—are not yet well quantified. This study investigates these mechanisms through full-factorial ITF experiments on thin-walled copper tubes using a three-axis CNC machine with a ball-tip tool over a 16 mm forming length, supported by explicit LS-DYNA shell simulations and quadratic response surface modelling. Numerical predictions show strong agreement with experimental measurements of both responses, with thickness prediction errors (MAPE) in the range of 4–5% and springback prediction errors below 3%, respectively, along with corresponding mean absolute error (MAE) values. Statistical analysis reveals a clear hierarchy of process influence: maximum thinning is governed primarily by axial feed, whereas springback exhibits nonlinear multivariate behavior dominated by radial feed, followed by axial feed and tool velocity, with significant interaction effects. The quadratic models, highly predictive for springback and sufficiently accurate for thinning, enable desirability-based multi-objective optimization, identifying 650 mm/min velocity, 0.35 mm axial feed, and 0.25 mm radial feed as an optimal operating condition. This parameter set limits thinning to approximately 0.45, reduces springback in both planes to 0.69 and 0.60, and achieves an overall desirability of nearly 0.7, thereby establishing a validated process window for defect-sensitive ITF of square tubes.