Abstract
Bending springback plays an important role in hydroforming of curved hollow components, and the effect will be more apparent with the increase of the strength of the material. In order to predict and eliminate the effect of springback on hydroforming process, springback of DP590 welded tube was investigated in computer numerical control (CNC) bending process using theoretical analysis, numerical simulation, and experimental methods. The effects of the bending angles, the diameter-thickness ratio d/t, and the relative bending radius R/d on springback are studied, and the influence factor of the weld position is considered. The theoretical and experimental results show that the springback of the DP590 welded tube with 65 mm in diameter and 2.6 mm in thickness varies within the range from 4.0 to 4.9 % and the amount of springback is influenced by the tube diameter and thickness. The springback reduces from 7.0 to 3.5 % when the diameter-thickness ratio is increasing from 10 to 40. On the contrary, the springback increases from 3.7 to 7.2 % when the relative bending radius is increasing from 1.2 to 4.0. The effect of weld position on springback is very little, but it has a negative effect on defects of hydroforming and wall thickness distribution. It is liable to crack when hydroforming if the weld locates on the outside or neutral layer of the bend. Finally, springback rules and weld effect are applied to form a control arm. A sound part had been successfully manufactured to avoid flash and crack defects considering the appropriate springback compensation and weld position.
Similar content being viewed by others
References
Kim SH (2007) Tool design for the tubular press forming of a rear suspension member with the finite element analysis. J Mater Process Technol 192-193(10):181–187
Heo SJ, Kang DO, Lee JH, Kim IH, Darwish SMH (2013) Shape optimization of lower control arm considering multi-disciplinary constraint condition by using progress meta-model method. Int J Autom Technol 14(3):499–505
Kim Y, Yang S, Sohn H, Park J, Choi S (2006) Finite element analysis to optimize forming conditions for lower control arm. Metall Mater Trans A 37(8):2539–2547
Kim J K, Kim S K, Son H J, Lee K H, Park Y C (2010) Structural design method of a control arm with consideration of strength. Proceedings of the 9th WSEAS Int Conference on Applied Computer and Applied Computational Science 149–152
Wang SG, Gao FS, Chen S (2014) The forming process simulation of magnesium alloy control arm of automobile and its mold design. Appl Mech Mater 494-495:262–265
Yoo J, Lee CY (2007) Topology optimization of a swing arm type actuator using the response surface method. Microsyst Technol 13(1):21–31
Yuan SJ, Han C, Wang XS (2006) Hydroforming of automotive structural components with rectangular-sections. Int J Mach Tools Manuf 46(11):1201–1206
Asnafi N, Nilsson T, Lassl G (2003) Tubular hydroforming of automotive side members with extruded aluminium profiles. J Mater Process Technol 142(1):93–101
Xie WC, Han C, Chu GN, Yuan SJ (2015) Research on hydro-pressing process of closed section tubular parts. Int J Adv Manuf Technol 80(5–8):1149–1157
Zhang WW, Han C, Yuan SJ (2016) Optimization of pre-form shapes by response surface methodology for hydro-forming of 780 MPa torsion beam. Int J Adv Manuf Technol 85:1227–1237
Saboori M, Champliaud H, Gholipour J, Gakwaya A, Savoie J, Wanjara P (2014) Evaluating the flow stress of aerospace alloys for tube hydroforming process by free expansion testing. Int J Adv Manuf Technol 72(9–12):1275–1286
Abedrabbo N, Worswick M, Mayer R, Riemsdijk IV (2009) Optimization methods for the tube hydroforming process applied to advanced high-strength steels with experimental verification. J Mater Process Technol 209(1):110–123
Souza TD, Rolfe BF (2013) Understanding robustness of springback in high strength steels. Int J Mech Sci 68(2):236–245
Al-Qureshi HA, Russo A (2002) Spring-back and residual stresses in bending of thin-walled aluminium tubes. Mater Design 23(2):217–222
Murata M, Kuboki T, Takahashi K, et al. (2008) Effect of hardening exponent on tube bending. J Mater Process Technol 201(1–3):189–192
Gu RJ, Yang H, Zhan M, Li H, Li HW (2008) Research on the springback of thin-walled tube NC bending based on the numerical simulation of the whole process. Comp Mater Sci 42(4):537–549
Zhang W, Han C, Xie W, Yuan S (2014) The effect of springback of CNC bending on hydro-formed sub-frame and compensation methods. J Harbin Institute Technol 46(7):36–39
Yu Z, Kong Q, Ma C, Lin Z (2014) Theoretical and experimental study on formability of laser seamed tube hydroforming. Int J Adv Manuf Technol 75(1–4):305–315
Ren N, Yang H, Zhan M, Zhang ZY, Qin YT, Jiang HM, Diao KS, Chen XP (2013) Strain distribution characteristics of welded tube in NC bending process using experimental grid method. Int J Adv Manuf Technol 66(5–8):635–644
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no competing interests.
Rights and permissions
About this article
Cite this article
Han, C., Feng, H. & Yuan, S.J. Springback and compensation of bending for hydroforming of advanced high-strength steel welded tubes. Int J Adv Manuf Technol 89, 3619–3629 (2017). https://doi.org/10.1007/s00170-016-9319-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9319-4