Significance-based optimization of processing parameters for thin-walled aluminum alloy tube NC bending with small bending radius

Thin-walled aluminum alloy tube numerical control (NC) bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element (FE) simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d 50 mm×1 mm ×75 mm and d 70 mm×1.5 mm×105 mm (initial tube outside diameter D0×initial tube wall thickness t0×bending radius R), and qualified tubes are produced.