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Article

Finite-Elements Modeling and Simulation of Electrically-Assisted Rotary-Draw Bending Process for 6063 Aluminum Alloy Micro-Tube

1
Laboratory for Space Environment and Physical Sciences, Harbin Institute of Technology, Harbin 150080, China
2
Key Laboratory of Micro-Systems and Micro-Structures Manufacturing of Ministry of Education, Harbin Institute of Technology, Harbin 150080, China
3
Shanghai Institute of Spacecraft Equipment, Shanghai 200240, China
4
Institute of Advanced Manufacturing and Modern Equipment Technology, Jiangsu University, Zhenjiang 212013, China
*
Author to whom correspondence should be addressed.
Academic Editor: Hardy Mohrbacher
Metals 2021, 11(12), 1956; https://doi.org/10.3390/met11121956
Received: 8 November 2021 / Revised: 23 November 2021 / Accepted: 24 November 2021 / Published: 5 December 2021
Bent micro-tubes have been frequently applied in electronics, medical devices and aerospace for heat transfer due to the increasing heat flux in high-density electric packages. Rotary-draw bending (RDB) is a commonly used process in forming tubes due to its versatility. However, the control of forming defects is the key problem in micro-tube bending in terms of wall thinning, cross-sectional deformation and wrinkling. In this paper, a three-dimensional (3D) finite-elements (FE) modeling of electrically-assisted (EA) RDB of 6063 aluminum alloy micro-tubes is developed with the implicit method in ABAQUS. The multi-field coupled behavior was simulated and analyzed during the EA RDB of micro-tubes. Several process parameters such as micro-tube diameter, bending radius, current density and electrical load path were selected to study their effects on the bending defects of the Al6063 micro-tubes. The simulated results showed that the cross-sectional distortion could be improved when electrical current mainly pass through the vicinity of the tangent point in the micro-tube RDB, and the cross-sectional distortion tended to decrease with the increases of current density and tube diameter, and the decreases of bending speed and radius. A trade-off should be made between the benefit and side effect due to electrical current since the risk of wall thinning and wrinkling may increase. View Full-Text
Keywords: finite-elements; electrically-assisted; rotary-draw bending; micro-tube; aluminum alloy finite-elements; electrically-assisted; rotary-draw bending; micro-tube; aluminum alloy
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MDPI and ACS Style

Wang, X.; Xu, J.; Ding, M.; Zhang, Y.; Wang, Z.; Guo, B.; Shan, D. Finite-Elements Modeling and Simulation of Electrically-Assisted Rotary-Draw Bending Process for 6063 Aluminum Alloy Micro-Tube. Metals 2021, 11, 1956. https://doi.org/10.3390/met11121956

AMA Style

Wang X, Xu J, Ding M, Zhang Y, Wang Z, Guo B, Shan D. Finite-Elements Modeling and Simulation of Electrically-Assisted Rotary-Draw Bending Process for 6063 Aluminum Alloy Micro-Tube. Metals. 2021; 11(12):1956. https://doi.org/10.3390/met11121956

Chicago/Turabian Style

Wang, Xinwei, Jie Xu, Minghan Ding, Yanhu Zhang, Zhenlong Wang, Bin Guo, and Debin Shan. 2021. "Finite-Elements Modeling and Simulation of Electrically-Assisted Rotary-Draw Bending Process for 6063 Aluminum Alloy Micro-Tube" Metals 11, no. 12: 1956. https://doi.org/10.3390/met11121956

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