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<p>The finite element simulation is an effective way for tube formability research based on free bending technology. To resolve the controversial issues regarding key parameters in the finite element model (FEM) establishment process and to significantly improve the simulation accuracy of tube-free bending, the study focuses on selecting and unifying key parameters to balance accuracy and efficiency in model development. An anisotropic constitutive model for the metal tube was established based on the Hill48 yield criterion, and its validity was verified by experiments. Then, a whole-tube model and a half-tube model were developed based on the anisotropic constitutive model. The results showed that the half-tube model demonstrated a 51.4% reduction in computation time with only a 0.98% loss in accuracy. Key findings include the following: (1) A mass scaling factor of 6000 enhances both stability and computational efficiency; (2) solid elements improve accuracy by 4.41% compared to shell elements, while shell elements reduce computation time by 90%; (3) a relative mesh density of 1.711 effectively balances precision and efficiency. The model was validated with a maximum error of 3.77%, providing a robust guide for the production of tube components.&#xa0;</p>

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Establishment and optimization of finite element models for accurate and efficient free bending of metal tubes

  • 期刊论文

  • 发表日期：

    2025年1月5日

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  • Zhenhua Xu,
  • Hua Wang,
  • Rongjing Hong

摘要

The finite element simulation is an effective way for tube formability research based on free bending technology. To resolve the controversial issues regarding key parameters in the finite element model (FEM) establishment process and to significantly improve the simulation accuracy of tube-free bending, the study focuses on selecting and unifying key parameters to balance accuracy and efficiency in model development. An anisotropic constitutive model for the metal tube was established based on the Hill48 yield criterion, and its validity was verified by experiments. Then, a whole-tube model and a half-tube model were developed based on the anisotropic constitutive model. The results showed that the half-tube model demonstrated a 51.4% reduction in computation time with only a 0.98% loss in accuracy. Key findings include the following: (1) A mass scaling factor of 6000 enhances both stability and computational efficiency; (2) solid elements improve accuracy by 4.41% compared to shell elements, while shell elements reduce computation time by 90%; (3) a relative mesh density of 1.711 effectively balances precision and efficiency. The model was validated with a maximum error of 3.77%, providing a robust guide for the production of tube components.