Integrating theoretical analysis, FE modeling-based microdefects, and experimental investigation to reveal the wrinkling behavior in internally supported thin-walled metallic tubes manufactured via FBF technology
Journal of Manufacturing Processes, cilt.172, ss.744-760, 2026 (SCI-Expanded, Scopus)
- Yayın Türü: Makale / Tam Makale
- Cilt numarası: 172
- Basım Tarihi: 2026
- Doi Numarası: 10.1016/j.jmapro.2026.05.078
- Dergi Adı: Journal of Manufacturing Processes
- Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, ABI/INFORM, Compendex, INSPEC, Materials Science & Engineering Collection (ProQuest), Pharma Collection (ProQuest), Technology Collection (ProQuest)
- Sayfa Sayıları: ss.744-760
- Anahtar Kelimeler: Free bending forming, Geometric microdefects, Golden section method, Internally supported thin-walled tubes, Wrinkling
- Atatürk Üniversitesi Adresli: Hayır
Özet
Wrinkling is a critical defect in the free-bending forming (FBF) process of thin-walled metal tubes, severely compromising dimensional accuracy and structural integrity. This study proposes an integrated approach that combines theoretical modeling, finite element (FE) simulation, and experimental validation to accurately predict the wrinkling behavior of AA5052 and SS304 tubes under internal support conditions. This model accounts for the influence of geometric microdefects on the formation of wrinkles and on energy consumption during forming. Among the evaluated buckling modes, the 7th-order mode demonstrated the lowest energy consumption and was selected as the optimal geometric microdefect. A three-dimensional dynamic explicit FE model was constructed using ABAQUS/Explicit, embedding these geometric microdefects to simulate wrinkling behavior during bending. The internal support force exerted by the core rod was quantified using a fitted relationship between eccentricity and wrinkle amplitude, enabling accurate replication of wrinkling conditions. The Golden Section (GS) method was employed to identify the most wrinkling-sensitive regions by evaluating the distribution of the wrinkling factor across varying forming ratios and compressive zones. The results reveal that the AA5052 tube exhibits significant wrinkling susceptibility at forming ratios between 40% and 80%, while the SS304 tube is most vulnerable at a forming ratio of 60%. Comparative analyses between FE simulations and experimental results confirmed the effectiveness of the proposed modeling approach in capturing wrinkle morphology, wall-thickness variation, and cross-sectional deformation. The findings demonstrate that introducing appropriately scaled geometric microdefects significantly enhances the predictive capability for wrinkling instability in internally supported thin-walled tubes formed by FBF.