FE simulation and response surface methodology for optimization of tube bending process

Abstract

In this paper Finite Element Simulation and Response Surface Methodology (RSM) were used in order optimize the tube bending process. In a first stage, the amount of cross section ovality and wall thinning of bent tubes are determined by using the Finite Element Simulation. In the second stage, on the basis of the FE Simulation results, RSM was used to develop two empirical models able to describe the relationship between the cross section ovality and wall thinning, respectively and two independent variables: relative bending radius (R/D) and relative tube diameter (D/t). The models were tested using the ANOVA method, which demonstrated that the solutions fit sufficiently precise the results obtained by FE Simulation. The statistical models were used to establish an optimal technological window for the tube bending process in order to obtain p roducts with an acceptable quality.