Experimental study on the effect of dies on wall thickness distribution in NC bending of thin-walled rectangular 3A21 aluminum alloy tube

To predict and control wall thickness distribution of thin-walled rectangular 3A21 aluminum alloy tube, the experiments of rotary draw bending process under multi-dies constraints are conducted. It is found that the thickness changing rates in middle bent zone are large, and the maximum values are obtained nearby the tube ridges. The effects of core die, pressure die, mandrel die, and bend die on thickness changing rate are significant. And the thinning rate increases with increase of core number, bend velocity, clearance between tube–pressure die interface and mandrel extension, but it decreases with increase of bend radius and boost velocity of pressure die. The thickening rate increases with increase of core number, boost velocity of pressure die and clearance between tube–wiper die interface, but it decreases with increase of bend radius and bend velocity.