Abstract
For the demand of energy conservation and security improvement, high-strength steel (HSS) is increasingly being used to produce safety related automotive components. However, cross-section distortion occurs easily in bending of HSS tube with rectangular section (RS), affecting the forming precision. HSS BR1500HS tube by rotary draw bending is taken as the study object and a description method of cross-section distortion is proposed in this paper. The influence on cross-section precision of geometric parameters including cross-section position, thickness of tube, bend radius etc. are studied by experiment. Besides, simulation of the rotary draw bending of HSS tube with rectangular section by ABAQUS are carried out and compared to the experiment. The results by simulation agree well with the experiment and show that the cross-section is approximately trapezoidal after distortion; the maximum of distortion exists at 45 ∼ 60° of the bending direction; and the absolute and relative distortion values increase with the decreasing of tube thickness or bending radius. Therefore, the results can provide a reference for the design of geometric parameters of HSS tube with rectangular section in rotary draw bending.
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