Tube bending analysis by finite element method and prediction of springback angle

In this research, an investigation of bending parameters of tubular profiles bent by tube bending machines during bending through Push Rolling method shall be conducted for those used in automotive industry. Tube bending process offers production of chassis parts with highly complicated geometries as single components so that it can reduce weight and manufacturing cost of the components hence it has been preferred in fields of aerespace and automotive. Precise degree of bending and proper cross-section area is of paramount importance in such fields where bent tubes are used. Cross-section distortion is the most widely confronted problem in tube bending process. In tube bending process, Rotary Draw, Push Rolling, Compression and Ram methods are utilized. Another significant factor affecting the degree of bending is the springback. Since bending radius is much larger in comparison to the die radius in the rotary draw bending, the springback occurs large scales depending on the cross-section and the material of the tube material. Springback behaviour of profiles with open and closed cross-section can be various depending on the dimensions and forms of the cross-section area, bending radii, and degree of bend. The distortions at the cross-section area of pipes are investigated. Because while thickening of the inner surface of a bending tube (the surface in vicinity of die) is observed, thinning on the extrados of the tube can be confronted. To sum up, what can be done to prevent such issues in tube bending shall be explained.