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<p>The bending of ultra-thin large tube is extremely difficult owing to the coexistence of wrinkling and overthinning. A novel tube hydro-bending was proposed to address the problem of severe wrinkling during the traditional hydro-bending process in manufacturing ultra-thin components. The proposed method changes the axial and circumferential stress distributions of the tube. The wrinkling behaviors on conventional and novel hydro-bending processes were investigated by numerical simulation and experiments. The oblique and transverse wrinkles occurred on the tube in the traditional tube hydro-bending. As the internal pressure increases, the length of wrinkles gradually decreases. In addition, it is not feasible to eliminate wrinkles in the bending process solely by increasing internal pressure during the traditional tube hydro-bending. The results show that the addition of a support device can suppress wrinkling behavior. Furthermore, the proposed novel method can effectively improve the distribution of wall thickness; the maximum thinning ratio of the bent tube was reduced from 15.13% to 12.25% by adding a self-sealing support. Eventually, a large bent tube (Φ 465 × <i>t</i> 0.8 × <i>R</i> 717.5&#xa0;mm) with no wrinkle was manufactured successfully when the pressure in the support device is 0.9&#xa0;ps and the pressure in the tube is 0.6&#xa0;ps.</p>

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A novel tube hydro-bending method for ultra-thin tubular components

  • 期刊论文

  • 发表日期：

    2025年6月10日

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  • YongPeng Zhuang,
  • Cong Han

摘要

The bending of ultra-thin large tube is extremely difficult owing to the coexistence of wrinkling and overthinning. A novel tube hydro-bending was proposed to address the problem of severe wrinkling during the traditional hydro-bending process in manufacturing ultra-thin components. The proposed method changes the axial and circumferential stress distributions of the tube. The wrinkling behaviors on conventional and novel hydro-bending processes were investigated by numerical simulation and experiments. The oblique and transverse wrinkles occurred on the tube in the traditional tube hydro-bending. As the internal pressure increases, the length of wrinkles gradually decreases. In addition, it is not feasible to eliminate wrinkles in the bending process solely by increasing internal pressure during the traditional tube hydro-bending. The results show that the addition of a support device can suppress wrinkling behavior. Furthermore, the proposed novel method can effectively improve the distribution of wall thickness; the maximum thinning ratio of the bent tube was reduced from 15.13% to 12.25% by adding a self-sealing support. Eventually, a large bent tube (Φ 465 × t 0.8 × R 717.5 mm) with no wrinkle was manufactured successfully when the pressure in the support device is 0.9 ps and the pressure in the tube is 0.6 ps.