Influence of mandrel-cores filling on size effect of cross-section distortion of bimetallic thin-walled composite bending tube

Abstract

Two new size factors of cross-section hollow coefficient and bending degree are introduced to reveal the size effect of bending forming of bimetallic composite tube. Hollow coefficient and bending degree can limit the commonly used bent tube to the size description range of (0, 2.00). The evolution laws of the cross-section distortion forms in the hollow coefficient-bending degree interval are revealed as well as the action of the mandrel-cores on the size effect. Results show the mandrel-cores filling can expand the forming limit of the bent tube, but also bring two other forming defects of wrinkle and rupture. The identification factor (hollow coefficient multiply bending degree) provides a method for querying the cross-section distortion forms of all composite bending tubes. In the identification factor interval (0, 1.00), the distribution area of bending forming defects of the composite tube is continuous. The thin-walled composite bending tube collapses when identification factor in (0, 0.39), wrinkles when identification factor in [0.39, 0.50), and ruptures when identification factor in [0.50, 1.00). The mathematical model of size effect is derived, by which the average cross-section distortion rate is found to distribute like a radial leaf in the hollow coefficient-bending degree qualified forming space. The best forming zone is hollow coefficient 0.46–0.68, and bending degree 0.25–0.47.