3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation
Ultra-high strength steel (UHSS) pipes find widespread application in the automotive industry. To address the challenges associated with forming complex structural parts from UHSS pipes, the three-dimensional free thermal bending (3D-FTB) technology for UHSS pipes based on a robotic arm and a bendin...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2023-11-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423030521 |
| _version_ | 1797301449553608704 |
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| author | Wang Jie Yang Chengshi Li Huaguan Liu Wenyi Guo Xunzhong Cheng Cheng Zheng Shuo |
| author_facet | Wang Jie Yang Chengshi Li Huaguan Liu Wenyi Guo Xunzhong Cheng Cheng Zheng Shuo |
| author_sort | Wang Jie |
| collection | DOAJ |
| description | Ultra-high strength steel (UHSS) pipes find widespread application in the automotive industry. To address the challenges associated with forming complex structural parts from UHSS pipes, the three-dimensional free thermal bending (3D-FTB) technology for UHSS pipes based on a robotic arm and a bending roller mold was firstly developed. A finite element simulation prediction model for accurately describing the forming process is established and discussed. In this paper, the thermal-mechanical coupling model of the material is established by Gleeble thermal tensile test and modified Arrhenius model. The effects of parameters such as current frequency, current density, axial feed rate, and quenching conditions on forming temperature and microstructure transformation are thoroughly investigated via finite element simulation analysis. The mechanical properties and potential defects of the pipe fittings after forming are analyzed and validated experimentally. The results demonstrate that the finite element simulation and analysis method based on the thermal-force coupling model of the BR1500HS UHSS pipe can accurately predict the forming process parameters. The optimal process conditions are identified as follows: current frequency of 55 kHz, current density of 650 A/mm2, and feed rate of 8 mm/s. Under these parameters, the austenite transformation rate of the pipe fittings reaches an impressive 98 % and the maximum tensile strength reaches 1540 MPa. Lastly, the overall wall thickness distortion rate of the formed pipe remains below 0.2 % and the bending rebound angle exhibits an average reduction of over 80 % compared to that under room temperature conditions. |
| first_indexed | 2024-03-07T23:21:43Z |
| format | Article |
| id | doaj.art-51ffa6c64c9c473e9a02674eaccbf0de |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-07T23:21:43Z |
| publishDate | 2023-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-51ffa6c64c9c473e9a02674eaccbf0de2024-02-21T05:28:41ZengElsevierJournal of Materials Research and Technology2238-78542023-11-0127837283853D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigationWang Jie0Yang Chengshi1Li Huaguan2Liu Wenyi3Guo Xunzhong4Cheng Cheng5Zheng Shuo6School of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 211167, China; Jiangsu Key Laboratory of Advanced Structural Materials and Application Technology, Nanjing, 211167, ChinaSchool of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 211167, China; Jiangsu Key Laboratory of Advanced Structural Materials and Application Technology, Nanjing, 211167, ChinaSchool of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 211167, China; Jiangsu Key Laboratory of Advanced Structural Materials and Application Technology, Nanjing, 211167, China; Corresponding author. School of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 211167, China.School of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 211167, China; Jiangsu Key Laboratory of Advanced Structural Materials and Application Technology, Nanjing, 211167, ChinaCollege of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, ChinaCollege of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, ChinaCollege of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211106, ChinaUltra-high strength steel (UHSS) pipes find widespread application in the automotive industry. To address the challenges associated with forming complex structural parts from UHSS pipes, the three-dimensional free thermal bending (3D-FTB) technology for UHSS pipes based on a robotic arm and a bending roller mold was firstly developed. A finite element simulation prediction model for accurately describing the forming process is established and discussed. In this paper, the thermal-mechanical coupling model of the material is established by Gleeble thermal tensile test and modified Arrhenius model. The effects of parameters such as current frequency, current density, axial feed rate, and quenching conditions on forming temperature and microstructure transformation are thoroughly investigated via finite element simulation analysis. The mechanical properties and potential defects of the pipe fittings after forming are analyzed and validated experimentally. The results demonstrate that the finite element simulation and analysis method based on the thermal-force coupling model of the BR1500HS UHSS pipe can accurately predict the forming process parameters. The optimal process conditions are identified as follows: current frequency of 55 kHz, current density of 650 A/mm2, and feed rate of 8 mm/s. Under these parameters, the austenite transformation rate of the pipe fittings reaches an impressive 98 % and the maximum tensile strength reaches 1540 MPa. Lastly, the overall wall thickness distortion rate of the formed pipe remains below 0.2 % and the bending rebound angle exhibits an average reduction of over 80 % compared to that under room temperature conditions.http://www.sciencedirect.com/science/article/pii/S22387854230305213D-FTBUHSS pipeInduction heatingNumerical simulationConstitutive equation |
| spellingShingle | Wang Jie Yang Chengshi Li Huaguan Liu Wenyi Guo Xunzhong Cheng Cheng Zheng Shuo 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation Journal of Materials Research and Technology 3D-FTB UHSS pipe Induction heating Numerical simulation Constitutive equation |
| title | 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation |
| title_full | 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation |
| title_fullStr | 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation |
| title_full_unstemmed | 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation |
| title_short | 3D free thermal bending of BR1500HS high-strength steel tube: Simulation and experimental investigation |
| title_sort | 3d free thermal bending of br1500hs high strength steel tube simulation and experimental investigation |
| topic | 3D-FTB UHSS pipe Induction heating Numerical simulation Constitutive equation |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423030521 |
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