Three-dimensional tube geometry control for rotary draw tube bending, Part 1: Bend angle and overall tube geometry control

Huazhou Lou, Kim A. Stelson

Research output: Contribution to journalArticlepeer-review

29 Scopus citations

Abstract

Traditional trial-and-error springback compensation methods have the problems of high scrap rate, low efficiency, high cost of fixtures and operator experience dependency. The method presented in this paper uses on-line measured springback data from the same batch to predict and compensate for springback. Because there are no springback data for the first bend, bend-rebend control is used to make the first bend to eliminate trial tubes. In addition to springback, relaxation and radial growth are also estimated and compensated for to make a bend more accurate. A process control method is developed to optimize the overall control strategy such that the overall tube error is minimized without increasing the required hardware accuracy. The optimal process control strategy has significantly higher accuracy than the traditional trial-and-error method. The details of statistical analysis of tube tolerance and adaptive bend correction algorithm are presented in Part 2 of the paper.

Original languageEnglish (US)
Pages (from-to)258-265
Number of pages8
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume123
Issue number2
DOIs
StatePublished - May 2001

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