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<p>The sizing process is a critical intermediate forming procedure in multipass rolling-brazing for producing double-wall brazed tubes (DWBTs). In the sizing process, the mandrel plays an essential role in accurately forming DWBTs and ensuring tight fitting of the inner and outer layers, which is of great importance for the success of the subsequent brazing operation, as well as the quality of the final product. However, achieving control over precise dimensions and uniform stress distribution in the formed tube remains a challenge. This study aims to obtain the optimal design parameters of an olive-shaped mandrel by investigating the effect of its key parameters, specifically the length and diameter of the mandrel head, on the forming quality of DWBTs during the sizing process. The results of experimental and numerical studies show that, with the increasing length and diameter of the mandrel head, the cross-section of the formed double-wall tube gets closer to an ideal roundness. An increase in the mandrel head length results in a more uniform stress distribution but a decreased uniformity in the wall thickness. In contrast, an increase in the mandrel head diameter improves the geometrical accuracy of the formed double-walled tube; however, the uniformity of the stress distribution decreases owing to the higher sizing force. Through a comprehensive analysis of multiple forming indices such as roundness, wall thickness distribution, and stress distribution, the optimal design parameters of the sizing mandrel are determined, offering practical guidance for achieving high-quality DWBT manufacturing.</p>

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Effect of mandrel on forming quality in sizing process of double-wall brazed tube

  • 期刊论文

  • 发表日期：

    2026年4月11日

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  • Qiao-Zhen Su,
  • Hong Sun,
  • Jun Ma,
  • Meng-Meng Liu,
  • Xuan-Cheng Hao,
  • Yu-Li Liu,
  • Heng Li

摘要

The sizing process is a critical intermediate forming procedure in multipass rolling-brazing for producing double-wall brazed tubes (DWBTs). In the sizing process, the mandrel plays an essential role in accurately forming DWBTs and ensuring tight fitting of the inner and outer layers, which is of great importance for the success of the subsequent brazing operation, as well as the quality of the final product. However, achieving control over precise dimensions and uniform stress distribution in the formed tube remains a challenge. This study aims to obtain the optimal design parameters of an olive-shaped mandrel by investigating the effect of its key parameters, specifically the length and diameter of the mandrel head, on the forming quality of DWBTs during the sizing process. The results of experimental and numerical studies show that, with the increasing length and diameter of the mandrel head, the cross-section of the formed double-wall tube gets closer to an ideal roundness. An increase in the mandrel head length results in a more uniform stress distribution but a decreased uniformity in the wall thickness. In contrast, an increase in the mandrel head diameter improves the geometrical accuracy of the formed double-walled tube; however, the uniformity of the stress distribution decreases owing to the higher sizing force. Through a comprehensive analysis of multiple forming indices such as roundness, wall thickness distribution, and stress distribution, the optimal design parameters of the sizing mandrel are determined, offering practical guidance for achieving high-quality DWBT manufacturing.