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• 63, 3, 361–376, 2015

Polish Academy of Sciences • Institute of Fundamental Technological Research (IPPT PAN)

National Engineering School of Metz (ENIM) • Poznan University of Technology

**Calculations of the Strains and Thicknesses of Pipe Elbows
**

on the Basis of Expressions Resulting from the EU Directive

for the Case of Large Strains

Zdzisław ŚLODERBACH

**Opole University of Technology
**

Faculty of Applications of Chemistry and Mechanics

Luboszycka 7, 45-036 Opole, Poland

e-mail: z.sloderbach@po.opole.pl

**The relations to calculate the maximum value of relative strains, which occur in a process of
**

bending of tubes on benders, in stretched layers of tubes, are presented in this work on the basis

of the EU Directive concerning production of pressure equipment. It has been shown that for

large deformations that occur during bending of the pipes on knees, logarithmic strain measures

(real) and relative strain measures give diﬀerent values of strain and equal wall thicknesses in

the bending zone. Reverse expressions were also derived to calculate the required initial wall

thickness of the tube to be bent, in order to obtain the desired wall thickness of a knee after

bending.

Key words: EU Directive, required thicknesses of pipe elbows, pipe bending processes, rela-

tive and logarithmic measures of deformation, required initial thickness of a bent tube.

1. Introduction

**According to the EU Directive on requirements in manufacturing of pressure
**

equipment presented in [1, 2] the measure of relative strain is used for calculat-

ing the value of deformation [3–9] and this is a measure of the maximum value

of the longitudinal component of the strain state for the case of ﬁrst-order sim-

pliﬁcation [10, 11]. In this paper, suitable equations will be derived for the three

main components of relative strains, which according to the formula from [1, 2],

reach their maximal values. Then, the expression for the minimum value of the

wall thickness in knee bending layer will be obtained. During tube bending on

knees of pipelines or other piping systems, great deformations of several tens

of percent are created [10–14]. Then, the used logarithmic measures (logarith-

mic measures are frequently used to analyze large and small deformations in

engineering practice) of strain will not be equal to the measures of the relative

this re- sults in thicknesses equal to those respectively calculated in the measures of loga- rithmic strain. Tube bending is treated as a process dependent on the angle of bending αb as a parameter. the actual thickness is used. three com- ponents of strain state: longitudinal. It will cause signiﬁcant diﬀerences in the calculations. But when for calculating of the state of deformation the expression contained in the EU Directive is used for the purpose of calculating the minimum (accept- able) wall thickness. except that instead of calculated thickness. 6. 13] is due to the fact that the expression in the . The expressions may be useful and can provide some criteria for the selection of appropriate method (technology) of pipe bending for components of pressure equipment (for example. depending on the dext and refers to the stretched layers. Diﬀerent values will be obtained from the use of these measures. namely when α = β = 0◦ and kαb = 180◦ . with or without a mandrel [17–23]). Conversely. commonly applied method in the technological theory of plas- ticity. Since the bent tube is a spatial element. according to simpliﬁcation of the ﬁrst order [10. The use of kinematically admissible ﬁelds of plastic deformation is a simpliﬁed. the required minimum initial thicknesses of the pipes to be bent will be also equal to those calculated in measures of logarithmic strain. According to the given classiﬁ- cation. 11]. taking into account the shift of neutral axis y0 and using the concept of kinematically ad- missible plastic strain ﬁelds. The EU Directive [1. with using drawing or pushing. The equations obtained in this way very well describe the experimental results presented in [17]. this expression is equal to the modiﬁed expression for the longitudinal component for the ﬁrst-order simpliﬁcation given in [10. The use in this work of the ﬁrst-order simpliﬁcation derived in [10] instead of generalized model of strain [12. In the paper [12] the derivation of expressions for generalized scheme of deformations was presented. 16]. ŚLODERBACH strain. These expressions are identical to the expressions used in practical appli- cations given in the papers [15. 2] also contains an empirical expression to calculate the required minimum wall thickness in stretched and compressed layers of bent knees. see [1. Given relationship for calculat- ing the deformation is expressed in measures of relative deformations. see [10–13]. 11]. This applies in particular to the conditions and requirements used to qualify the process of tube bending and to assessment of bent pipes and elbows designed for elements such as water-tubular boilers. Further discussion and development of this problem will be presented in Sec.362 Z. circumferential and radial (in thickness) were derived. which will be demonstrated in the respective examples. see [12]. The aim of this work is to draw attention to the possible consequences that may arise from the use of expressions for calculating the deformation in tube bending process according to the EU Directive. when at the points of stretched layers the state of maximum deformation is reached. 2].

. rint = dint /2. in engineering practice and for tube bending [3–7. There is no unique deﬁnition in the Directive for the Rm . 1. (2. Eq. . R0 – radius of the neutral surface following bending. since in general R 6= Rm . gi – actual thickness of a bend within the bending zone (i = 1 for elongated layers. αb ∈ h0◦ . As it results from Fig. dint are respectively the external and internal diameter of a bent tube. Rm ∈ hR − y0 max . are the same as in the generalized model [11]. 2Rm where O – longitudinal (axially) tensile strain in relative terms. α ∈ 0◦ . logarithmic measures of strain. Ri (Śloderbach [11]). The parameters of bending process are presented in Fig. Ri – larger actual radius of a bend associated with longitudinal strain. In Fig. which are not included in the EU Directive. i = 2 for compressed layers). where dext . CALCULATIONS OF THE STRAINS AND THICKNESSES. 90◦ i. Rm is a mean bending radius. 363 EU Directive corresponds to the expression for maximum elongation component of deformation for this simpliﬁcation. g0 – initial thickness of a bent tube. 180◦ i. R – bending radius. The other two components of deformation (circumferential and radial). Ri. 2] the expression to calculate the deformation in the stretched layers in the process of tube bending in accordance with EU Directive is pre- sented dext (2. are most often used in description of strain state of many plastic forming processes. Basic assumptions and relations In the papers [1. β is actual angle determined at the planes perpendicular to the bending plane. 1. α2b . that is β ∈ h0◦ . The examples of calculation results in our work show that the values of relative strain are diﬀerent than those obtained with the use of logarithmic strain measures (real measures). α – actual angle of the bending zone determined at the principal bending plane and at planes parallel to it. 14. . This could be for example the arithmetic or geometric mean of bending radius R and (R − y0 max ) or other value in the range Rm ∈ hR − y0 max . If y0 = 0 then R = Rm . rext and rint – external and internal radius of a bent pipe. where R0 = R − y0 . 1. 21]. due to their practical meaning. 2. 13. y0 – displacement of the neutral surface (axis) with respect to the initial position. This may cause some problems in assessment of pipe bending technology and estimation of manufacturing of a knee. where αb – active bending angle measured over the bending zone. but the wall knees and the required minimum wall thickness of bent tube are equal.1) takes into consideration the shift of the neutral bending axis by the mean bending radius Rm . On the other hand.1) O= .

k – technological-material coeﬃcient dependent .42 α b (3. In the EU Directive [1.2) y0 ∼ = λ0 rm cos(kα) − cos k . 2] the pressure tubes are assumed as thin-walled when s∗w ≤ 0.05. dint = dext − 2g0 . re 2 where rm – mean radius of the bent tube. (where s∗ = g0 /dext .1) y0 = rm . rm = rint + g0 /2 (Fig.10 and maximal dext = 160 mm. the author considers only cold bending of metal tubes of the assumed technological wall thickness s∗ ≤ 0. 3. valid for bending zones.364 Z.42 (3. then s∗w = s∗ /(1 − 2s∗ ). determining displacement of the neutral axis. Expression for the displacement of the neutral axis In [24] the author derived the following approximate expression for displace- ment of the neutral axis: 0. re The extended expression. When s∗w = g0 /dint . re – relative radius of bending. ŚLODERBACH Fig. In this paper. Geometrical and dimensional quantities pertaining to tube bending processes. 2). respectively). is 0. g0 and dext – initial thickness and external diameter of the bent tube. re = R/dext . 1. obtained by the author and presented in [12].

when α = 60◦ . where αpl – angle of a plateau zone [10–12]. then 2α0 = kαb = 180◦ . 365 Fig. i. results in coeﬃcient k being lower (tends to the unit. ∞) . It seems that in the case of majority of metallic materials it is suﬃcient when k ∈ h1. coeﬃcient k expresses a ratio of the bending angle α0 to a real value of the bending angle αb . [10–13. and at a more ﬁtted expanding mandrel (segment with an adjusted external diameter) with rich lubrication of the mandrel and the tube interior. 2. e. Obviously. (see. then k = 180◦ /αb . If α0 = 90◦ . then (α0 = αb + αpl ). etc. 6i . for example as in [9–12]. within the bending zone the two angles are equal (α0 = αb ). 3i. determining a bending zone range in the bent zone. theoretically k ∈ h1 .e. it appears that coeﬃcient k allows to include (indirectly and in part) some eﬀects of friction between the mandrel and the bent tube wall. CALCULATIONS OF THE STRAINS AND THICKNESSES. When the bent angle α0 = kαb = 180◦ . This coeﬃcient is deﬁned during ex- periments. Thus. plastic materials bent at elevated temperatures (hot.. 17. semi-hot or preheated bending) and bent with a greater radius R. where α0 – bend angle (the angle by which a template or a former is rotated). Schematic of the elbow cross section and its characteristic parameters. on the bent tube material and the applied bending technology. The case of more ductile. soft.. When the plateau zone was formed.. 180◦ i. ∞) but for the analyzed method α0 ∈ h0◦ . k = α0 /αb . From the recognized tests and calculations it even appears that k ∈ h1. . k → 1).g. In theory for spirals α0 ∈ h0◦ . then 3α0 = kαb = 180◦ . 20]). For elbows bent to 180◦ . . .

. tube material. and the coeﬃcient k. see Eq. the maximum displacement of the neutral axis can be equal to ∼25% of a diameter value of the tube which is going to be bent.42 re rm . clearances. (3. more plastic material for the bent tube. In the compressed layers. Thus. forces of friction between the bent tube and the bending machine device. for example.125) or (0. in practice it is recommended to limit the considered bending method to the radii (R ≥ 1. (3. in the considered ranges re and s∗w . ŚLODERBACH Coeﬃcient λ0 determines characteristic technological-material parameters of the tube bending process such as type of mandrel.366 Z. The estimated maximum value y0 . eﬀects resulting from non-unbounded upsetting may be smaller. Taking some additional calculations into ac- count. shape of the template and the ﬂatter. (3. This can cause lower values of the coeﬃcient λ0 . sin β0 = y0 /rext ≈ y0 /rm . bending technologies and tube materials.2).10).5 × dext . s∗w = 0. 1 × dext i and more thin-walled tubes (s∗w ≪ 0. bending method (cold. the maximum (for instance for R = 1. hot. 2 β1 and β2 are the angles determined in elongated and compressed layers.5 × dext ). Thus. relationships which do not include dis- placement of the neutral axis y0 can be applied to strain analysis. Greater displacements of the neutral axis may be caused by another bending technology because. strip pressure. They are more intense along the perimeter of displacement of the bent tube material to the sides.2) it appears that for very small bending radii R ∈ h0. In Eq.05). for some ranges (R and s∗w ). increase of rigidity of the bending machine and so on/etc. tubes are often bent with use of a force which is opposite to the force rotating the template so as to obtain a suitable stress distribution in the cross section. they were applied in [13] for precise description of fundamental experiments presented in [17]. From the extended Eq.2) it also appears that displacement of the neutral axis is inﬂuenced not only by the bending radius and the tube thickness (thin-walled) but also by a suitable technology. can be in practice even lower owing to a suitable selection and set up of tooling of the bending machine.5) – relative (related to the external diameter of the bent tube) displace- ment of the neutral axis is y0 /dext ≈ 10%. application of bending at el- evated temperatures. In Fig.00 < s∗w ≤ 0. if (cos(kα) = 1 and cos k α2b = 0) then y0 = y0 max ∼ = λ0 0.1) and (3. (3.2) it is also shown that there are three additional parameters determining displacement of the neutral axis and its position in the bending zone: the bending angle and the angle determining a position of the point inthe bending zone.00 < s∗ ≤ 0. bending parameters and the tube material. removal of clearances. Pressure tubes which are most often used in pipelines for power industry and other tube installations of power engineering devices are usually in the range (0. upward and along the bent axis. with preheating). However. rigidity of the bending machine.2).0 × dext . From Eqs. The introduced limitations concerning the tube bending parameters cause that. see expressions (3.1) and (3.03 and λ0 = 0. self-hot.

after formal transformations. When (α = β1 = 0◦ and kαb = 180◦ ).3)1 and (3.5) and (3. for the case of ﬁrst-order simpliﬁcation [10. ε′2 = .4). Since the bent pipe is spatial. . where ′ and d′ = d +2g ′ . 2Rm dext g0 and 2Rm + dext d′1l ′ g1l (3. dext g0 and 2Rm + dext cos β1 cos (kα) − cos k α2b ϕ′1 = ln . (3. ϕ′3 are logarithmic components of plastic deformations for the ﬁrst-order simpliﬁca- tion.3).3) d′ − dext g′ − g0 ε′2 = 1r . ε′3 = . ε′2 . 2Rm (3. 2Rm (3. ε′3 = 1r . then Eqs. are minimum wall thickness of d′1r = dint +2g1r 1l int 1l 1r 1l bent knee in tension layers determined for the relative and logarithmic measures of strain. a proper analysis of the plastic strain requires the determination of three major components of strain. . ε′3 are relative com- ponents of plastic deformations for the ﬁrst-order simpliﬁcation and ϕ′1 .5) ε′1 = . g . 2Rm dext g0 Expressions (3. and g . ϕ′2 = ln . have the following forms: ′ dext cos β1 cos (kα) − cos k α2b ε1 = . ϕ′3 = ln .4) d′1l ′ g1l ϕ′2 = ln . dext g0 where d′1r and are the outer minimum diameters of knee in stretched layers de- termined for the relative and logarithmic measures of strain. (3. CALCULATIONS OF THE STRAINS AND THICKNESSES. ϕ′2 . respectively.6) ϕ′1 = ln .6) are empirical relationships mutually arising from their engineering deﬁnitions measures of strains and adoption of . 367 According to the assumptions that the derived expressions for strain com- ponents in tube bending processes are identiﬁed with plastic strains (it appears that in the angular measure the elastic strains are related to the main bending angle equal to some degrees [10–13]) we conclude that ε′1 . respectively. These components in relative and logarithmic measures according to symbolism accepted in mechanics of solids and according to designations used in papers of Śloderbach [10–13] when (y0 6= 0 and exchanging R on Rm ).4)1 take their maximum values as dext d′1r − dext ′ −g g1r 0 (3. 11]. (3. ϕ′3 = ln .

Hence. g0 4. ŚLODERBACH incompressibility condition of plastically deformed materials. Incompressibility condition is valid for majority of metallic materials [25].6) respectively to incompressibility conditions (3. (3.3).8)2 . after transformations we obtain the following expression for the appropriate minimum wall thickness of the knee in the apex points of tension layers: (α = β = 0◦ and kαb = 180◦ ). (3. for the case when (y0 6= 0 and R 6= Rm ).9) ′ g0 − g1l Kg′ l = .1) dext g0 2Rm dext g0 s ′ (dext − 2g 0 ) dext − 2g0 2 Rm dext g0 g1l = − + + . 20]: ′ g0 − g1r Kg′ r = .4). 16.8)1 and (3. Formulas for calculating the coeﬃcients of the maximum thinning of tube wall with respect to its initial thickness are the following [15. Calculation of the required minimum wall thickness Substituting components of relative plastic strain (3. are the followings: r 2 ′ ε(i) = exp ln2 (1 + ε′1 ) + ln2 (1 + ε′2 ) + ln2 (1 + ε′3 ) − 1. 3 (3.5) and (3.5) and (3.8) ϕ′1 + ϕ′2 + ϕ′3 = 0.368 Z. for the case of great deformations. (3. (4.6). g0 (3.7) r ′ 2 ′2 ϕ(i) = (ϕ + ϕ′2 2 + ϕ′3 2 ). dext d′ − dext g1r ′ −g 0 dext d′1r − dext dext g1r ′ −g 0 + 1r + + · + · 2Rm dext g0 2Rm dext 2Rm g0 ′ d − dext g1r − g0 ′ ′ ′ dext d1r − dext g1r − g0 + 1r · + · = 0. The equations for intensity of plastic strain for strain measures (3. 4 4 2Rm + dext where g1r′ and g ′ are the minimum wall thicknesses of bent knee in tension layers 1l determined for the relative and logarithmic measures of strain. d′1r = dint + 2g1r . respectively and ′ . 3 1 The conditions of plastic incompressibility of the material have the following form: ε′1 + ε′2 + ε′3 + ε′1 ε′2 + ε′1 ε′3 + ε′2 ε′3 + ε′1 ε′2 ε′3 = 0.

8 × dext ). Based on Eqs. Thus.6) and (4.6) and (3. ε′3 ∼ = 0. (3. Let the mean bending radius Rm = 80 mm (Rm ≈ 1.2781. For the case of large strains. corresponding to the above calculated thicknesses. 26–31]. . ′ ′ ′ ′ These are calculated minimum wall thicknesses of the bent knee in stretch layers expressed in real (logarithmic) and relative measures of strain.187. Kg′ l ∼ = 0.2) g1r = g1l .2454. [3. 369 Example 1. g1l = 3. 10–13.5 × 4. Based on the above results and on the data from Fig. and the dimensions of bent pipe: φ44. CALCULATIONS OF THE STRAINS AND THICKNESSES. obtained on the basis of the EU Directive [1.0378. The thinning coeﬃ- cients. respec- tively.7).5). ε′2 ∼ = −0. (3.1869. (3. 4 we obtain the fol- lowing equality: ′ ′ (4.2).187.0385.3) and expressions (3.g. on the basis of formulas (3. (4. .1) we obtain ε′1 ∼ = −0. e. have the following values Kg′ r ∼ = 0.659 mm. ϕ′1 ∼ = 0. see.5 mm.9) it results that (4. the following inequalities in strains occur: . ϕ3 = −0.5).3) Kg′ r = Kg′ l .. ∼ ∼ ∼ ∼ ϕ2 = −0.659 mm. 2]. such strains occur during bending of tubes in stretched layers (which are valid for each bending radius R or Rm and geometric dimensions of bent tube) and based on equalities (4.2069 and g1r = 3.

′.

.

′.

.

′.

.

′.

(4. .4) ε′1 > ϕ′1 .

ε2 .

< .

ϕ2 .

. .

ε3 .

< .

ϕ3 .

including the pipe bending [10–13. and (4. calculated in exam- ple 1. in all cases exceed the value of acceptable thinning. which. On the other hand. The values of thinning coeﬃcient of the wall thickness.8 × dext (as in example 1) is “sharper”. This results from the fact that bending with the radius Rm ∼ = 1. For knees made of thin-walled . 26]. and also in operating and resistance. it is known that logarithmic measures of strain.08. 17–20. This fact may cause some problems in designing and technology. due to their practical properties. according to Korzemski [20] for the outer diameter of tube bent with radius Rm ≥ 3 × dext is equal to Kg′ all = 0. are usually used to describe the state of strain in several plastic forming processes.5) ε′(i) > ϕ′(i) . The above examples of computational results show that the values of relative strains calculated according to the EU Directive are diﬀerent than those obtained with the use of logarithmic (real) strain measures.

8)1 and (3. . Determination of the required initial thickness of bent tube This is the inverse problem to the one considered in the previous section. requirements of EU-PN (PN – Polish Standards) or regulations of the UDT (Oﬃce of the Polish Technical Supervision.8 × dext ). for example. dext g0r 2Rm dext g0r and ′ g1 (dext + 2g1 )(2Rm + dext ) (5. Then. on the basis of formulas (5. see [15.5) and logarithmic (3. the required (desired) wall thickness g1 will be given that satisﬁes. Now. g1 is a required (desired) minimum wall thickness of the knee in the apex point of stretched layers.2) g0l = .25 × dext . ŚLODERBACH metal on appropriate benders (with rotating template and during upsetting [10– 13.1) it also results that if the bending radius Rm tends to inﬁnity.5 mm and the required wall thickness of the knee in the apex (middle) point of stretched layers g1 = 4.459 mm and g ′ = 5. obtained respec- tively for logarithmic and relative measures of strain. 16]). technological and operational requirements.1) and (5. after trans- formations we obtain the following expression for appropriate initial (starting) required thickness of the wall of tube to be bent in the stretched layers: dext ′ ) 2(g1 − g0r ′ g1 − g0r ′ ) dext 2(g1 − g0r ′ dext g1 − g0r (5.495 mm.370 Z. The ini- tial (starting) required thickness g0 of wall of the tube to be bent is stud- ied/examined/investigated/researched. Substituting the components of plastic strains.6) respectively.1) + + ′ + · + · ′ 2Rm dext g0r 2Rm dext 2Rm g0r ′ ) g − g′ 2(g1 − g0r ′ ) g − g′ dext 2(g1 − g0r 1 0r 1 0r + · ′ + · · ′ = 0. 0l These are computed required initial wall-thickness values.8)2 . to incompressibility condition (3. outer diameter of tube dext = 44. resistance and construction conditions. depending on values of outer diameter of bent tube based on EU Directive.15). relative (3. Example 2.2) after calculations we obtain g0r′ = 5. 17–24] and bent with the radius Rm ≥ 1. the thinning of wall can be smaller than 15% (Kg′ < 0. respectively. From formulas (4. then the values g1r ′ and g ′ tend to value 1l g0 . Let the mean bending radius Rm = 80 mm (Rm ≈ 1. bending angle kαb = 180◦ . and that means the lack of bending eﬀect. 5. 2 [Rm (dext + 2g1 ) + dext g1 ] ′ and g ′ are required initial wall thickness values expressed through rel- where g0r 0l ative and logarithmic strains.5 mm.

for bent tube with dimensions φ44. 3. Variation of the minimum wall thickness values (gl′ l .5×4. From formulas (5. . CALCULATIONS OF THE STRAINS AND THICKNESSES. .5 [mm]. when Fig. required value of initial thickness of the tube to be bent is determined on the basis of expressions (5. are presented in Fig. The method of using the relations derived in this section is the following: for given parameters of bending described with average bending radius Rm and for given geometric dimensions of the tube to be bent (l × dext ) and for required value of wall thickness of bent knee g1 . 6.1) and (5. Results and discussion Changes in the minimum thickness of the bent knee (g1r ′ and g ′ ) depen- 1l ding on the average bending radius Rm .2). 371 On the basis of these results and the data from Fig.5 mm pipe. 5 we obtain the following equality: ′ ′ (5. with the use of relative and logarithmic measures of strain.1) and (5. As can be visible from the plots. 3. then the values of g0r ′ req and g0l req tend to g1 and that means the lack ′ of results of bending. glr ′ ) of a bend with bending radius Rm for φ44.5×4.2) it also results that when bending radius Rm tends to inﬁnity. respectively. .3) g0r = g0l .

(4. strains decrease and both measures of strain be- come nearly equal. if a re- quired minimum wall thickness of a bend for the pipe dext = 44. It is just the opposite when the bending radius Rm increases.5 mm is g1 = 4. ŚLODERBACH bending radius Rm decreases. g0l ′ ) with bending radius Rm . the diﬀerences in thicknesses are increased (diﬀerences between the ′ or g ′ and a required thickness g ) and vice versa. see Fig. the diﬀerences in thicknesses are increased (dif- ferences between in the initial thickness g0 and actual thickness g1r ′ or g ′ ). are presented in Fig. 5.3).5 mm. (5. The 1l use of relative and logarithmic measures of strain causes the diﬀerences in the calculations of intensity of plastic strains. Variation of the initial wall thickness (g0′ r . When bending radius Rm strives to inﬁn- ity then calculated thicknesses (g1r ′ and g ′ ) strive respectively to thickness g 1l 0 (g0 = 4. 4. 3. 4.2).5 mm) and that means the lack of bending. Fig.372 Z. Graphs of initial thicknesses of the bent pipes depending on the value of the average bending radius Rm . When initial thickness g0r 0l 1 bending radius Rm increases. Analogously to the graph presented in Fig. appli- cation of the relative and logarithmic strain measures determines that g0l′ = g′ .3) and inequal- . 0r At the end it should be mentioned that equalities (4.5 mm. when the required (desired) thickness of the wall of the bent knee is g1 = 4. when the bending radius Rm decreases. derived at this point (which are used to determine the initial thickness of the pipe to be bent). When using the reverse dependencies.

5. derived in this work. (4. 20] producing accuracy of a few percent. In graphs in Figs. g ′ ) were presented. These simpliﬁcations also take into account. stretched and compressed.5). in addition to the advantages mentioned previously. 12. these obtained with the use of rela- for (g1r 1l 0l 0r tive measures of strain in stretched layers (according to the EU Directive [1. Selection ﬁrst-order simpliﬁcations of logarithmic and relative measures of strain provides. (4. 2]) with those obtained with the use of logarithmic measures. 373 ities (4.5 mm pipe.4). 13] that the use of logarithmic (real) measures of strain very well describes (even with accuracy of about 1 %) exper- imental data found in [17–21] and author’s own data. the eﬀect of even lowering with the angle of bending and mutually proportional (due to the . Fig. CALCULATIONS OF THE STRAINS AND THICKNESSES. ε′(i) ) of a bend with bending radius Rm for φ44. This comparison leads to inequalities (4. Variation of intensity of plastic deformation values (ϕ′(i) . 3 and 4 the results of respective calculations ′ . . It means that. during real processes of bending tubes on benders. in fact computational strains resulting from expression included in the EU Directive were compared with experimental data included in [17.4). in both layers. will be also met for each bending radius Rm and all geometric dimensions of bent tube and for (R > y0 max ). It was shown in the papers [10. see Fig. . very good accuracy of description of experimental data.5 × 4. 5. g ′ ) and (g ′ .5) and ﬁnal conclusion that intensity of plastic strains calculated using the EU Directive are greater than the logarithmic ones.

see [11]. Remarks and conclusions 1. e. for solution for small deformations we should use other relations. e. 4. On the other hand..g.8)1 . including tube bending (see. which will cause that actual position of the inert layer will be less moved “downwards”..1)1 and (5. are most often applied to de- scription of strain state in many forming processes. in real technologi- cal processes of bending pipes. we should use the relations (3. However. .1)1 and (5. In order to obtain the required (in accordance with the Directive concern- ing pressure equipment and its production. 3. due to their practical properties. This work can be treated as the ﬁrst step and the next steps could be devel- opment of nomograms and tables for bending tubes of various dimensions (dext × g0 ) or (dint × g0 ) for various Rm applying expressions (3. plastically deformed material of pipe will move more “sideways” and less swell in compression layers. e.g. Due to the occurrence of these eﬀects. ŚLODERBACH eﬀects of thinning and ovality of cross section) of the outer stretched layers and simultaneous shifting “downwards” (in the direction of the center of curva- ture and rotation). (see. 2. included in [1]) values of strain and the thickness of bent knees and the initial wall thickness of tubes to be bent for large deformations. but the mini- mum wall thicknesses are equal.1) valid for large deformations. The simpliﬁcations in the formulas for the longitudinal (axial) strain thus contain in numerator the value of dext in- stead of di .. 17–24]) the inert layer of plastic bending. The above examples of computational results show that the relative inten- sity of plastic strains are higher (for small and large strains) than those obtained with the use of logarithmic strain measures (real). the results are diﬀerent. 3–5 results that diﬀerent values of components of plastic deformations and intensity of plastic deformations counted in relative and logarithmic measures give the same walls thicknesses in bent pipes. The UE Directive contains dependence on dext and not on dint . (4.g. 7.1) derived in this work and (3. (4. (4. When initial thicknesses g0l or g0r are calculated depending on dext or dint .5).5) and from graphs in Figs. During the bending of tubes on a mandrel with a trackpad and using a pro- ﬁled strip with an adjustable clamp and with minimum clearances between the tools and the walls of the bent pipe. see [11].5).4). (see. [10–13. 17–24]).374 Z. [10–13. we have some physical justiﬁcation for the use of simpliﬁed expressions of ﬁrst degree. 17–21]). From inequalities (4. This fact may cause some problems in designing and technology and also in strength and operation. logarithmic measures of strain. [10–13.

. 1. shape of working tools. References 1.. Sawczuk A. Oxford. 6. Hill R. 3. (point 9. 2002. 1999. 375 5. Eﬀect of strain hardening and normal anisotropy on al- lowable values of strain and stress in pipe-bending processes. . Życzkowski M. Van Nostrand Reinhold Company. Theory of plasticity [in Polish]. We should remember that tube bending is not a free process but depends on bender. 2014. . Śloderbach Z. “Manufacture”. The European Directive concerning pressure installations.. 1990. Śloderbach Z. 1–6.. 25–33 and 48. 15. 3–20. 14.. Racibórz. Requirements concerning manufacturing [in Polish]. The solution of the problem of pipe bending on benders in the frame- work of nonlinear solid mechanics is diﬃcult due to complex relations be- tween strains and deformations.. bending parameters such as Rm .4 Tube Bents. Clarendon Press. 2. [Eds. 9–14. Calculations and checking of wall thickness of bent tubes [in Polish]. 1. Śloderbach Z. Plasticity theory.]. Genaralized model of strains during bending of metal tubes in bending machines. CALCULATIONS OF THE STRAINS AND THICKNESSES. 17–24]. Publishing House of Wrocław University of Technology. tube material and other factors [1. New York. expression 9.. Journal of Theoretical and Applied Mechanics. PWN-Nijhoﬀ. 1981.A. 52. 1981. Technical requirement. Combined loading in the theory of plasticity. 13. Śloderbach Z.. 2. . 8. its stiﬀness. 1999. 2009 (earlier: Draft Standard EN UFPV “Unﬁred Pressure Vessels” – Part 4. Plasticity – theory and applications. Strauchold Sz. 5. Theory of elasticity and plasticity [in Polish]. Engineering Transactions.. Zdankiewicz M. CEN/TC54/267 JWGB N277. Mathematical theory of plasticity. Perzyna P.. Wrocław.2. Gabryszewski Z. 1988. May. 2001... Macmillan Publishers. New York. EN 13445-4 “Unﬁred Pressure Vessels” – Part 4: Fabrication.. Technical Inspection (Dozór Techniczny). Śloderbach Z. PWN. Wrocław. Olszak W. Warszawa.. tube dimensions (dext ×g0 ).. 1975. Approximate methods for evaluating strains in pipe bending processes [in Polish]. London. 12. Publishing House of Wrocław University of Technology. A model of deformation geometry in pipe bending processes. Lubliner J. Warszawa- Alpen aan den Rijn. rev. 4. 1093–1106. 4. Macmillan Publishers. 2.. 843–859. 7. 11. Engineering plasticity. 2000. Some problems of mechanics in pipeline bending processes [in Polish]. Rechul Z. Team Work.. Poland 1991. Mendelson A. Journal of Theoretical and Applied Mechanics. 1998.. Johnson W. 5. 1996). Technical Inspection (Dozór Techniczny). type of applied mandrels. 38. Steam Boilers Factory “RAFAKO” S. 1.2-4). 1985. 47. Mellor P. see [26–31] and is open to further studies. 10. WT-1/0/R.B. 9.

Ren N. 308–327. Society of Manufacturing Engineers. 27. Springer-Verlag. Śloderbach Z. Journal Mécanique Theoretique et Applique. PWN.. Strength calculations [in Pol- ish].. Warszawa.. Issue I. 28. 129–145. Berlin. 1985. Tian Y. 24. 751–759. WNT. Springer-Verlag.. Received March 16.. Guangjun L.W. Fourth Edition – forming. 2010. 22. Berlin – Hei- delberg. Xudong X. 2015..D. Mathematics and Mechanics of Solids. 25. 23.. Continuum mechanics and theory of materials. PWN. Franz W. 21. Plastic-deformation analysis in tube bending.. 60. 1982.. Conditions of uniqueness of the solution of boundaryvalue problem and bifurcation criteria. USA 2001. Numero special.376 Z. 1969. 1987. 2011. Theory of plasticity in metalworking [in Polish]. 36. Veilleux R. Gronostajski J.. Deformation behavior of medium strength TA18 high-pressure tubes during NC bending with diﬀerent bending radii. 15. 1991. 1961. .T. Warszawa. Wick Ch. Tool and manufacturing engineers hand- book. On the termination of the process of ﬁnite plastic de- formations. Szuwalski K.. Pajak J. 24. Szczepiński W. Mei Z.C.B. General requirements. Życzkowski M. Generalized coupled thermoplasticity taking into account large strains: part I. Springer-Verlag. Matzenmiller A. Huttel C.. Chinese Journal of Aeronautics.. Michigan... International Journal of Plasticity. 29. 2015.. 657–664. 2002. 35–44. Thin-walled pipe bending [in Polish].. Pressure installations. 19. Zhang Z.. Extension of generalized plasticity to ﬁnite deformations and structures. 9.. Das Kalt-Biegen von Rohren. 20. Warszawa.. H. Numerisch gesteuerte Rohrkaltbiegemaschinen. Praktisches Rohrbiegen. 17. UDT Conditions. He Y. 1996.D. Team Work. 1971. Finite deformation plasticity with strain induced anisotropy and shear banding. Fundamentals of metal-working processes [in Pol- ish]. Berlin. Bending behaviors of large diameter thin walled CP-Ti tube in rotary draw bending.. Progress in Natural Science: Materials International. Li. 1999. 1. 18... managers and technicians.. 77. A reference book for manufacturing engineers. Haupt P.. 5255–5276. Zhiqiang J. International Journal of Pres- sure Vessels and Piping. Volume 2. Pęcherski R. 2000. 21. 2003. accepted April 23. Journal of the Materials Processes and Technology. 175–186. Korzemski J. ŚLODERBACH 16. 401–412. 31. 30.. Tang N. Yang H. (WUDT-UC-WO-O/02:10).. 2011. 12. Grunow O.. 26. Werkstatt und Betrieb.F. Warszawa. 3. Dearbon. Benedict J. Gabryszewski Z. Franz W..

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