Significance Analysis of Processing Parameters on Wall Thinning in Tube Bending

Tube bending is a complex process with multi-factor coupling effect and multiple defects occurring. The wall thinning, as one of the important defects in tube bending, determines the bending quality. In this study, taking thin-walled 6061-T4 Al-alloy tube with Φ50.8×t0.889×R101.6mm (outer diameter D × wall thickness t × bending radius R) as the objective, the significance of processing parameters on the wall thinning degree is studied using the orthogonal test under ABAQUS/Explicit platform. The results show that: 1) the bending radius, the clearance between the tube and the pressure die, the friction between the tube and the pressure die, the clearance between the tube and the pressure die, the clearance between the tube and the mandrel and the friction between the tube and the mandrel affect the wall thinning significantly, while the coefficient of boost velocity, the number of mandrel balls, the friction between the tube and the wiper die, the mandrel extension length and the friction between the tube and the bending die have little effect on the wall thinning degree.