Simulation and optimization of the free bending process of aluminum alloy 6061 pipe
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摘要: 金屬管材是工業領域中結構承重、輸送氣體和液體的重要部件。自由彎管成形技術有助于實現管件生產的高精度、高性能、高效率和數字化，其精度控制理論和成形技術的研究具有重要的工業應用價值。本文選擇直徑 30 mm 壁厚 2.0 mm 的鋁合金管材6061為仿真優化對象，通過相關基礎實驗獲得材料的基本力學數據，用于仿真模型參數的表征。同時，結合管材壓彎實驗驗證本構模型成形預測的有效性。在完成仿真模型表征和驗證的基礎上，對鋁合金管材的自由彎曲成形過程進行仿真模擬，分析對比了影響自由彎曲成形的各工藝參數，確定了該工況下最優的移動模與管材間隙大小、摩擦系數和進給速度等。該研究有助于優化管材空間自由彎曲成形工藝，具有一定的工業應用價值。Abstract: Metal pipes are the important components of structural load-bearing and conveying gas or liquid in the industrial field. However, the final forming profile obtained with the traditional bending process highly depends on the forming mold; the forming profile is simple, but the mold cost is relatively expensive. Thus, it is difficult for wide promotion on the bent pipe with a complex profile, especially for small batch production. The free bending process as a method of solving this problem is attracting a lot of attention. This process can achieve precision forming of the pipe without a forming mold. The pipe can be bent into different radii by adjusting the relative positions of the fixed die and mobile die. This process not only reduces the manufacturing cost but also improves the forming quality. The development of the free bending process will help to achieve high precision, high performance, high efficiency, and digitization of the industrial production of the metal pipes. In this study, an aluminum alloy 6061 pipe with a diameter of 30 mm and wall thickness of 2.0 mm was chosen. Its mechanical parameters were obtained by a tensile test of the axial and circumferential specimens of the pipe, and the obtained parameters were used for the parameter characterization of the chosen constitutive model. Meanwhile, a press bending test was carried out to validate the chosen model. Afterward, the pipe space free bending process was simulated by the finite element method, and the results were analyzed. Finally, the optimal values of the process parameters, including the shape of the mobile die, the size of the clearance of the mobile die and pipe, the frictional coefficient, and the feed speed of the pipe, were determined. This study has a great significance in the application of pipe space free bending forming process.
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圖 1 彎管工藝外對比。（a）傳統彎管；（b）自由彎管
Figure 1. Comparison of tube bending processes: (a) traditional technique; (b) free bending
圖 2 鋁合金管材6061拉伸實驗及壓彎實驗。（a）軸向拉伸；（b）環向拉伸；（c）壓彎
Figure 2. Tensile test and press bending test of aluminum alloy 6061 pipe: (a) axial tensile test; (b) circumferential tensile test; (c) press bending test
圖 3 實驗與仿真結果對比。（a）軸向拉伸；（b）環向拉伸；（c）壓彎
Figure 3. Comparison between the simulation and experimental results: (a) axial tensile test; (b) circumferential tensile test; (c) press bending test
圖 5 自由彎曲成形后的應力、應變及壁厚云圖
Figure 5. Stress, strain, and thickness nephogram of free bending forming
圖 6 沿管材進給長度的應力應變及壁厚變化曲線。（a）應力；（b）應變；（c）壁厚
Figure 6. Stress, strain and thickness curve of bending along the feed length of pipe: (a) stress; (b) strain; (c) thickness
圖 9 不同間隙的成形結果。（a）應變云圖；（b）壁厚變化曲線；（c）截面橢圓度變化曲線；（d）推進力變化曲線
Figure 9. Results of bending with different clearance: (a) strain contour; (b) thickness curve along the feed length of pipe; (c) ovality curve along the feed length of pipe; (d) pushing force curve
圖 10 壁厚、橢圓度、殘余應力和應變變化曲線。（a）平均壁厚減薄率和截面橢圓度；（b）殘余應力和應變
Figure 10. Thickness reduction, ovality, residual stress and strain curve of bending: (a) thickness reduction and ovality; (b) residual stress and strain
圖 11 不同摩擦力下成形結果。（a）成形云圖；（b）平均壁厚減薄率和截面橢圓度變化；（c）殘余應力和推進力變化
Figure 11. Results of bending with different frictional coefficients: (a) forming nephogram; (b) average thickness reduction and ovality; (c) residual stress and pushing force
圖 13 不同速度下應力、推進力、壁厚和橢圓度變化曲線
Figure 13. Stress, pushing force, thickness, and ovality curve with different velocities
圖 14 5和50 mm·s?1進給速度的成形結果
Figure 14. Forming result of bending with different velocities
表 1 鋁合金管材6061模型參數
Table 1. Model parameters of aluminum alloy 6061 pipe
Density/(g·cm?3) Young's modulus /MPa Yield stress /MPa Q/MPa b C/MPa a 2.76 66788.2 297.98 720.802 14.537 720.802 14.537 
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