Process parameter optimization for thin-walled tube push-bending using response surface methodology

In this paper, the response surface methodology (RSM) and finite element (FE) simulation were applied to optimize push-bending process parameters of thin-walled tube with polyurethane mandrel. The objective present work is predict optimal set including length diameter ratio mandrel (L/D), friction coefficient between die ( $${\mu }_{1}$$ ), }_{2}$$ Poisson’s $$\upsilon$$ ) obtain qualified bent tubes. Three empirical models developed describe relationship quality addition, significant factors affecting forming analyzed using analysis variance (ANOVA) each model. Response surfaces constructed study effect parameter on Finally, optimization window maximum thinning rate $$\varphi$$ less than 20%, thickening $$\psi$$ 17%, cross-section ovality $$\xi$$ 5% was established. Qualified tubes 144 mm, wall thickness 2 bending radius 280 mm formed experimentally by following established window.