Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure M/s Hero MotoCorp, Limited

Format:

Book

Conference/Event

Author/Creator:

Rajwani, Ishwar, author.

Contributor:

Khare, Saharash

Conference Name:

Symposium on International Automotive Technology (2026) (2026-01-28 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the annealing process ensures they are stress-free prior to bending, facilitating a more controlled analysis of their deformation6. The simulation results reveal significant geometric alterations in the bent region, including changes in ovality and wall thickness, which are heavily influenced by the bend radius and angle7. The residual stress analysis indicates a combination of tensile and compressive stresses that could jeopardize the pipe's structural integrity8. Furthermore, deformation in the bend zone can lead to welding issues such as uneven fit-up, altered section modulus, and irregular weld profiles, all of which can diminish weld joint performance9. To address these challenges, a conservative approach was adopted in our fatigue analysis using FE-Safe, applying the lower bound of weld material properties to account for potential weld imperfections stemming from bending10. These simulation outcomes are critical for evaluating the fatigue life of weld joints and comprehending how bending affects the pipe's long-term performance11. Ultimately, this research aims to enhance the reliability and efficiency of piping systems, especially in trellis structures, by improving the accuracy of fatigue simulations12. The insights gleaned will aid in optimizing bending processes, refining weld joint designs, and supporting the development of robust tubular structures for demanding applications13

Notes:

Vendor supplied data

Publisher Number:

2026-26-0370

Access Restriction:

Restricted for use by site license