颗粒芯模对T2铜管弯曲成形质量的改善研究

朱英霞; 王磊; 元琛; 陈炜; 李晖

doi:10.3969/j.issn.1674-6457.2025.12.025

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (12) : 241-249. DOI: 10.3969/j.issn.1674-6457.2025.12.025

铜合金成形

颗粒芯模对T2铜管弯曲成形质量的改善研究

朱英霞^*, 王磊, 元琛, 陈炜, 李晖

作者信息 +

Improvement of Forming Quality in T2 Copper Tube Bending with a Granular Mandrel

ZHU Yingxia^*, WANG Lei, YUAN Chen, CHEN Wei, LI Hui

Author information +

文章历史 +

摘要

目的探究颗粒芯模填充对T2铜管数控绕弯成形质量的影响机制,分析其在控制截面塌陷、抑制壁厚减薄与减轻损伤方面的效果,提高弯曲构件的成形精度与服役可靠性。方法建立基于Drucker-Prager本构模型的颗粒介质芯模的有限元模型,并通过实验验证该模型的可靠性。在此基础上,系统研究颗粒芯模对管材绕弯成形过程中截面塌陷率、壁厚减薄率及损伤因子分布的影响规律,并与无芯模填充、刚性芯模填充和PE芯模填充3种填充条件做对比分析。结果颗粒芯模填充时的平均截面塌陷率（9.94%）显著低于无芯模填充时的,并随弯曲角的增大逐渐稳定;颗粒芯模填充时的平均壁厚减薄率（8.55%）明显低于刚性芯模（10.18%）与PE芯模的（10.47%）;颗粒芯模对应的管材弯曲最大损伤值（0.88）低于刚性芯模（0.93）与PE芯模的（0.90）。结论颗粒芯模在截面稳定性、壁厚均匀性和损伤控制三者之间实现了较优平衡,综合性能优于传统刚性芯模与PE芯模的综合性能。其柔性填充体在弯曲过程中逐步被压实,既可提供有效内部支撑,又能减缓应力集中,为高精度管材弯曲制造提供了可靠新方案。

Abstract

The work aims to investigate the effect of granular mandrel filling on the forming quality of T2 copper tubes in numerical control (NC) rotary draw bending, to analyze its efficacy on controlling cross-sectional collapse, suppressing wall thinning, and reducing damage, thereby improving the forming accuracy and service reliability of bent components. A finite element model of the granular mandrel based on the Drucker-Prager constitutive model was established and validated through experiments. The effects of the granular mandrel on the cross-sectional collapse rate, wall thinning rate, and damage distribution during the tube bending process were systematically studied. A comparative analysis was conducted against three other conditions of no mandrel, a rigid mandrel, and a polyethylene (PE) mandrel. The average cross-sectional collapse rate with the granular mandrel (9.94%) was significantly lower than that without a mandrel and stabilized gradually with the increasing bending angle. The average wall thinning rate with the granular mandrel (8.55%) was notably lower than that with the rigid (10.18%) and PE mandrels (10.47%). The maximum damage value obtained with the granular mandrel (0.88) was also lower than that with the rigid (0.93) and PE (0.90) mandrels. The granular mandrel achieves an optimal balance among cross-sectional stability, wall thickness uniformity, and damage control, demonstrating overall superior performance compared to traditional rigid and PE mandrels. Its flexible filling medium becomes progressively compacted during bending, providing effective internal support while mitigating stress concentration. This offers a reliable new solution for high-precision tube bending manufacturing.

导出引用

朱英霞, 王磊, 元琛, 陈炜, 李晖. 颗粒芯模对T2铜管弯曲成形质量的改善研究[J]. 精密成形工程. 2025, 17(12): 241-249 https://doi.org/10.3969/j.issn.1674-6457.2025.12.025

ZHU Yingxia, WANG Lei, YUAN Chen, CHEN Wei, LI Hui. Improvement of Forming Quality in T2 Copper Tube Bending with a Granular Mandrel[J]. Journal of Netshape Forming Engineering. 2025, 17(12): 241-249 https://doi.org/10.3969/j.issn.1674-6457.2025.12.025

中图分类号： TG356

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