Three-dimensional finite element modeling of rotary-draw bending of copper-titanium composite tube

• Published in: International journal of advanced manufacturing technology Vol. 106; no. 5-6; pp. 2377 - 2389
• Main Authors: Zhu, Y. X., Chen, W., Tu, W. B., Guo, Y., Chen, L.
• Format: Journal Article
• Language: English
• Published: London Springer London 01.01.2020; Springer Nature B.V
• Subjects: Bimetals; CAE) and Design; Coefficient of friction; Computer simulation; Computer-Aided Engineering (CAD; Contact pressure; Copper; Coulomb friction; Damage; Dies; Draw bending; Engineering; Equivalence; Finite element method; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Mechanical properties; Media Management; Modelling; Organic chemistry; Original Article; Plastic deformation; Shearing; Springback; Three dimensional models; Titanium; Tubes; Bending forming simulation; Section deformation; Bimetal composite tube; Springback
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-019-04781-0

The copper-titanium bimetallic composite bent tube, which could integrate the advantages of physical, chemical, and mechanical properties of two materials, shows an urgent application demand prospect in mechanical manufacturing, marine operations, and other industrial fields. This paper develops a research on the modeling of rotary-draw bending of copper-titanium composite tube by using two kinds of grid elements S4R and C3D8R, respectively. The contact problem of base tube and covered tube is set as coulomb friction contact mode, whose optimal friction coefficient is obtained by pressure-shearing experiment and its simulation. The springback model is established by considering the contact action of the two tubes. Finally, the S4R shell FE model is compared with the C3D8R solid FE model from the two aspects of section deformation and springback. It is found that the shell element model is accurate in predicting the springback and section deformation, while the solid element model has a large deviation from the experimental results in predicting the section deformation. In order to gain a deeper understanding of the plastic deformation behavior of the bimetallic composite tube, the tangential stress, equivalent stress, equivalent strain, and damage values have been studied. Results show that (1) there is no significant uneven deformation between the base tube and the covered tube, which will not produce obvious wrinkling and section distortion even without the filling of the mandrel dies. (2) Sliding and stratification are existing between the base tube and the covered tube in the bending process. (3) The force of the dies on the base tube is transmitted through the side surface contact between the base tube and the covered tube. (4) The maximum damage value of the covered tube is larger than that of the base tube. This research will promote the development of precise plastic processing technology and play a role in the research of secondary plastic forming of metal composite tubes.