Numerical Simulation Of Wrinkling For Rotary Draw Bending Process Of Thin-walled Rectangular Tube

Aluminum alloy thin-walled rectangular waveguide tube is a key component widely used in the field of radar and radio communication system, and the rotary draw bending is the main forming method of rectangular waveguide. But wrinkling, distortion, tension crack etc are easily produced during the rotary draw bending process, especially the wrinkling seriously influence the quality of rectangular waveguide. Therefore, the wrinkling mechanism and the influencing laws of processing parameters on wrinkling in the bending process have been investigated systematically by using the 3D-FE numerical simulation technology. The achievements of this research are important to the development of rectangular tube bending technology and the determination and optimization of processing parameters. A brief introduction to the project and its main results are as follows:The primary mechanical property data of 3A21 aluminum alloy thin-walled rectangular tube has been obtained through the experiment, and then the constitutive equation has been established. Based on solving some key technological problems of the modeling in the rotary draw bending process of thin-walled rectangular tube, a 3D Elasto-plastic dynamic explicit FE model of the process has been established under the environment of the dynamic explicit FEM code ABAQUS/Explicit. And both computation accuracy and efficiency are taken into account during the establishing process of the model. And the reliability of the model has been verified by literature. The establishment of the model lay a foundation for the research on the wrinkling mechanism and the influencing laws of processing parameters on the process.Then, based on the model established above, the distribution laws of tangential stress and tangential strain have been investigated during the different stages of the bending process, and the variation rule of compression deformation area of the inner side of the tube has been also analyzed. The results indicate that the size and the relative position of the compression deformation area nearly keep unchanged with the progress of the bending process, and the bending angle at which the wrinkling is produced during the initial stage of bending process is less than 40°. The results of...