Abstract
In order to achieve the precision bending deformation, the effects of process parameters on springback behaviors should be clarified preliminarily. Taking the 21-6-9 high-strength stainless steel tube of 15.88 mm × 0.84 mm (outer diameter × wall thickness) as the objective, the multi-parameter sensitivity analysis and three-dimensional finite element numerical simulation are conducted to address the effects of process parameters on the springback behaviors in 21-6-9 high-strength stainless steel tube numerical control bending. The results show that (1) springback increases with the increasing of the clearance between tube and mandrel Cm, the friction coefficient between tube and mandrel fm, the friction coefficient between tube and bending die fb, or with the decreasing of the mandrel extension length e, while the springback first increases and then remains unchanged with the increasing of the clearance between tube and bending die Cb. (2) The sensitivity of springback radius to process parameters is larger than that of springback angle. And the sensitivity of springback to process parameters from high to low are e, Cb, Cm, fb and fm. (3) The variation rules of the cross section deformation after springback with different Cm, Cb, fm, fb and e are similar to that before springback. But under same process parameters, the relative difference of the most measurement section is more than 20% and some even more than 70% before and after springback, and a platform deforming characteristics of the cross section deformation is shown after springback.
Keywords
Introduction
High-strength 21-6-9 stainless steel (0Cr21Ni6Mn9N) bent tubes currently have been increasingly used in hydraulic, fuel, or oxygen transportation systems for advanced aircraft and spacecraft due to its excellent properties such as high strength, corrosion resistance and oxidation resistance. 1 Among various bending methods such as compress bending, stretch bending, roll bending and push bending, the numerical control (NC) bending, under multi-tool constraints as shown in Figure 1, is a feasible one for achieving stable and accurate bending of the high-strength stainless steel tube (HSSST). When the die is removed, the inevitable springback phenomenon occurs due to the extrados elongation and intrados compression deformation and even shows more significantly due to the high ratio of the yield strength to elastic modulus of the HSSST. The springback causes the decrease of the bending angle and the increase of bending radius and thus affects the connection and sealing performance of tubes with other parts as well as the internal structure compact. Since the springback closely relates to the bending history, and that is affected by process parameters. Therefore, in order to realize the effective control springback and the precision bending, the effects laws and degrees of the process parameters on springback in NC bending of 21-6-9 HSSST should be studied.

Schematic diagram of NC tube bending.
Up to now, great efforts have been carried out on the springback prediction and control in tube bending using analytical, experimental and numerical methods, while most studies focused on Al-alloy, Ti-alloy and low-strength stainless steel tube. Few concerned the springback of the HSSST. Tang 2 used plastic deformation theory to calculate the stress distributions and the bending moment for springback calculation. Zhang 3 derived an approximate calculation formula for springback angle and radius based on the analyses of stress and strain distribution in tube bending. Al-Qureshi and Russo 4 deduced an analytical model for the prediction of the springback and residual stress distributions with assumptions of ideal elastic plastic material, plane strain condition, absence of defects and “Bauschinger effect.” E and Liu 5 presented an analytical model in which time-dependent springback was associated with strain hardening for 1Cr18Ni9Ti stainless steel tube, and the formulae of time-dependent springback, time-independent springback and total springback were deduced using the model. By experiments, Wu et al. 6 obtained the effects of the temperature, bending speed and grain size on the springback of the wrought magnesium alloy AM30 tubes during rotary draw bending. Li et al. 7 experimentally studied the effects of forming parameters on springback of thin-walled 6061-T4 Al-alloy tubes in NC bending. Liu et al. 8 investigated the effects of bending angle, relative bending radius, relative tube diameter and material properties on springback of 1Cr18Ni9Ti, LF6 and T2 tubes in NC bending by experiments.
By the numerical simulation of the whole process (bending tube, retracting mandrel and unloading) for thin-walled 1Cr18Ni9Ti tube, 9 it was discovered that the total springback angle considering retracting mandrel was much smaller than that not considering retracting mandrel with maximum difference between them being 107.34%. Li et al. 10 revealed the nonlinear springback characterization and behaviors of high strength Ti-3Al-2.5V tube by finite element (FE) analysis. Also by the FE analysis, the geometry-dependent springback behaviors of thin-walled Al-alloy 6061-T4 tube on rotary draw bending were revealed by Li et al. 11 Sözen et al. 12 addressed the springback phenomena of steel tube NC bending under the interactions between the geometrical and mechanical parameters and developed a surrogate model to predict fast the springback for a given combination of parameters. Using the numerical simulation, Zhan et al. 13 investigated the springback mechanism for larger-diameter thin-walled CT20 Ti-alloy tube and proposed a two-level springback compensation method. Jiang et al. 14 studied the coupling effects of material properties and bending angle on springback angle for medium-strength TA18 Ti-alloy tube NC bending based on explicit/implicit FE code of ABAQUS. Recently, Fang et al. 15 achieved the effect rules of material parameters and geometry parameters on springback of 21-6-9 HSSST in NC bending. Zhang et al. 16 analyzed the sensitivity of material parameters on springback of high strength TA18 tube in NC bending using the numerical simulation and the multi-parameters sensitivity analysis method.
In addition, in the aspect of sheet bending springback, Behrouzi et al. 17 presented an analytical approach for springback analysis based on inverse algorithm, and the optimum die shape was obtained for producing the product in a few trials by inverse springback modeling. Lajarin and Marcondes 18 investigated the influences of process and tool parameters on springback of high-strength steel and obtained the significant parameters from high to low were blank holder force, tool radius and friction condition. Choudhury and Ghomi 19 studied the effects of 11 process parameters on springback of aluminum sheet in V-bending by Taguchi orthogonal array design and bending tests. The above results and methods provide beneficial information for springback prediction and control of 21-6-9 HSSST in NC bending.
In order to realize precision NC bending forming of HSSST, in this work, taking the 21-6-9 HSSST of 15.88 mm × 0.84 mm (outer diameter D × wall thickness t) as the objective, using the multi-parameter sensitivity analysis and FE numerical simulation method, the effects rules and the sensitivity degrees of process parameters on springback were studied, and the effects rules of the 21-6-9 HSSST springback on cross section deformation were further clarified.
Research methods
Description of multi-parameter sensitivity analysis method
Sensitivity analysis is a kind of the system analysis method as regards the stability of the system, which shows the trends and degrees of the system characteristics deviating from the benchmark status with the change of the influence factors. In actual system, decisions of the system characteristics for influence factors usually are different physical quantities, which have different units. Thus, the influence factors need to have a dimensionless processing. The relative errors δp and
The ratio is defined as the sensitivity value Sk(ak) of the influence factors ak,, as shown in equation (2)
When |Δak|/ak, is in smaller case, Sk(ak) can be approximate representation as equation (3)
where Sk(ak) (k = 1, 2,…, n) are a set of dimensionless non-negative real number, and the higher the value is, the more sensitivity the P to ak, is. Thus, the sensitivity of P to ak, can be obtained by comparing the values of Sk(ak).
Modification of multi-parameter sensitivity analysis
In equation (3), the function relationship f(ak) between P and ak must be established before a sensitivity analysis. But not all the P of the research object and the ak have a certain function relationship. While for the complex system, using numerical method expressed the relationship between the P and the ak requires a large amount of data to ensure the fitting precision. Thus, equation (3) is modified, and the modified of the multi-parameter sensitivity analysis model is shown in equation (4), namely, every two adjacent fitting date will have a slope value between them, and finally, the average value of these slopes is taken as the sensitivity value
where m is the number of the ak under each process condition,
For the sensitivity analysis of 21-6-9 HSSST NC bending springback process, the system characteristics P refer to the springback angle Δθ = θ − θ′ and springback radius ΔR = R′ − R (shown in Figure 2), and the influence factors ak (k = 1, 2,…, n) refer to the process parameters including the clearance between tube and bending die Cb, the clearance between tube and mandrel Cm, the friction coefficient between tube and bending die fb, the friction coefficient between tube and mandrel fm and the mandrel extension length e. Because of the influence factors of the HSSST NC bending springback process were so many, and the influences rules were complex, therefore, the FE model was established as a system model under ABAQUS platform, and all of the analysis was carried out by the FE simulation.

Schematic of tube springback after bending deformation.
Explicit/implicit three-dimensional FE model of the whole NC bending process for HSSST and its validation
According to the actual tube NC bending process, an elastic plastic three-dimensional finite element (3D-FE) model of the whole NC bending process including bending tube, retracting mandrel and unloading is established under ABAQUS platform as shown in Figure 3. The detailed solutions involved in FE modeling can be found in the literature.21,22 The explicit algorithm was employed for solving the bending tube and retracting mandrel process, while the implicit one was used for unloading computation. The results from bending tube and retracting mandrel simulation in ABAQUS/Explicit were directly imported into ABAQUS/Standard. The geometrical nonlinearity was included, and the specified damping factor was used to stabilize implicit iteration procedure in springback analysis. Double precision was employed for the bending process and the single precision for the springback analysis. The mass scaling factor of 2000 was utilized to improve the computation cost with neglected inertia effect using the convergence analysis in bending simulation.

Explicit/implicit elastic plastic 3D-FE model of the whole NC bending process for 21-6-9 HSSST.
The tube was discretized by four-node doubly curved thin shell element S4R, while four-node bilinear quadrilateral rigid element R3D4 was used to model the relative rigid dies. Different mesh density was used to the tube and die surfaces with the element size of 1.5 mm × 1.5 mm and 2 mm × 2 mm, respectively. The mechanical properties of the 21-6-9 HSSST (shown in Table 1) were obtained by the uniaxial tension test according to the GB/T228-2002, in which a piece of complete tube specimen was directly cut from the raw tube by the wire cut. And the Ludwigson model
Mechanical properties of 21-6-9 HSSST.
Friction coefficients in various contact interfaces.
Rough means no relative slip between tube and clamp die.
The boundary constraints were applied by two approaches to realize the actual NC bending process: “displacement/rotation” and “velocity/angular velocity”. Both bending die and clamp die were constrained to rotate about the global Z-axis simultaneously; pressure die was constrained to translate only along the global X-axis with the same linear speed as the centerline bending speed of bending die; wiper die was constrained along all degrees of freedom; the mandrel was fixed from all degrees of freedom during bending process, while the mandrel was retracted along the global X-axis after the bending process finished. The smooth step amplitude curves were used to define the smooth loading of the bending die, clamp die, pressure die and mandrel to ensure little inertial effects in explicit FE simulation of the quasi-static process. For the unloading process, all dies were removed and a fixed boundary condition was applied to avoid the rigid motion as shown in Figure 3.
In order to validate the reliability of the FE model, the experiments were carried out by the NC tube bender SB-12 × 3A-2S as shown in Figure 4. The experimental conditions are as follows: the specification of 6.35 mm × 0.41 mm (outer diameter D × wall thickness t) for 21-6-9 HSSST; the bending speed ω is 0.4 rad/s; the push assistant speed of pressure die Vp is 8 mm/s; the bending radius R is 20 mm; the bending angle θ are 30°, 60°, 90°, 120°, 150°, and 180°, respectively; and the dry friction condition is used to the contact interfaces.

Illustration of NC tube bender SB-12 × 3A-2S.
Figure 5 shows the comparison between experimental results and simulation results. As shown in Figure 5(a), it is found that the FE simulation for springback angles agrees with the experimental results with the maximum relative error of 15.5%. Besides the direct comparisons, the validation of the FE model is also carried out for the cross section deformation degree ΔD, 22 as shown in Figure 5(b). The comparisons show that the FE prediction can capture the bending deformation precisely with the maximum relative error less than 7%, which is the basic for reliable prediction of the springback. Thus, the FE model is reliable, which can be used to study the springback law of 21-6-9 HSSST in NC bending.

Comparison of simulation results and experimental results: (a) springback angle and (b) cross section deformation degree.
Results and discussion
Research procedure
Taking the specification 15.88 mm × 0.84 mm of 21-6-9 HSSST as the objective, the fluctuation ranges of process parameters are used as shown in Table 3 according to the actual situation. The study on the effects rules of process parameters on springback and springback on cross section deformation was carried out. The bending radius R is 47.64 mm, the bending angle θ is 180°, the bending speed ω is 0.4 rad/s, the push assistant speed of pressure die Vp is 19.056 mm/s, the clearance between tube and clamp die is 0 mm, the clearance between tube and mandrel is 0.05 mm, the clearance between tube and other dies is 0.1 mm, the mandrel extension length is 3.5 mm, and the friction coefficients in various contact interfaces are listed in Table 2.
Range of process parameters for analysis.
Value in bold fonts is taken as the standard bending condition.
Effects of process parameters on springback
Figure 6 shows the effects of process parameters on springback of 21-6-9 HSSST in NC bending. As shown in Figure 6(a), with the increasing of the clearance between tube and mandrel Cm, the trends of both springback angle and springback radius increase on the whole. The results are similar to the analysis results of the thin-walled 6061-T4 Al-alloy tube 7 and the thin-walled 1Cr18Ni9Ti stainless steel tube. 25 The reasons are that first, the larger Cm makes the axial tensile force acting on the tube decrease, and then the bending moment increases since the neutral layer shifts toward outside of the bending center. Second, the larger Cm is, the larger cross section deformation (shown in Figure 10(a)), which leads to the bending stiffness decreases. All above reasons make the springback increase.

Effects of process parameters on springback: (a) Cm, (b) Cb, (c) fm, (d) fb and (e) e.
Figure 6(b) shows the springback angle and radius first increase and then remain little changed with the increasing of the clearance between tube and bending die Cb, which is according with the results of the thick-walled medium strength TA18 tube. 26 This is because that when the Cb is less than 0.25 mm, the cross section deformation degree increases with the increasing of the Cb as shown in Figure 10(b), then the bending stiffness decreases, and as a result the springback increases. While when the Cb is larger than 0.25 mm, the deformation degree variation is not obvious with the increasing of the Cb. Figure 7 shows that the maximum tangent compressive stress first decreases and then the variation is not obvious with the increasing of the Cb, which further proves the above results.

Effects of Cb on maximum tangent compressive stress.
Figure 6(c) shows the springback angle and radius increase with the increasing of the friction coefficient between tube and mandrel fm. The main reasons are that first, the axial tensile force increases with the increasing of the fm, and then the bending moment decreases, which leads to reduce the springback; second, the wrinkling wave degree η 22 increases with the increasing of the fm as shown in Figure 8, and the wrinkling occurs near clamp side with larger the fm, which leads to the springback increase significantly. 24 Thus, the synthetic action of the both makes the springback increase.

Effects of fm on wrinkling wave degree η.
Figure 6(d) shows the effects of the friction coefficient between tube and bending die fb on springback angle and radius. It is found that the springback angle and radius increase linearly with the increasing of the fb, which is in line with the analysis results of the thick-walled medium strength TA18 tube. 26 This is because that the larger the fb, the smaller the tube bending deformation force, namely, the axial tensile force decreases and the bending moment increases with the increasing of the fb, which leads to the springback increase.
Figure 6(e) shows the effects of the mandrel extension length e on springback angle and radius. It is discovered that the springback angle and radius decrease with the increasing of the e. The results are similar to that of the thin-walled 6061-T4 Al-alloy tube, 7 but different form that of the thin-walled 1Cr18Ni9Ti stainless steel tube. 25 These are because that first, the axial tensile force increases with the increasing of the e, and then the bending moment decreases, which causes the springback angle and radius decrease. Second, the cross section deformation decreases with the increasing of the e as shown in Figure 10(e), and then the corresponding bending stiffness increases, which leads to the springback decrease.
Sensitivity analysis for springback
The sensitivity values Sk(ak) of springback angle Δθ and springback radius ΔR are calculated using equation (4), as shown in Table 4. In order to get a more direct analysis, the sensitivity values in Table 4 are further shown in Figure 9.
Sensitivity values of different process parameters.

Sensitivity comparison between springback angle and springback radius to process parameters.
Figure 9 shows the sensitivity comparison between springback angle and springback radius to the process parameters. It is found that the sensitivity of springback radius to the process parameters is larger than that of springback angle for 21-6-9 HSSST in NC bending process. The most sensitive process parameter for springback of 21-6-9 HSSST in NC bending is the mandrel extension length e, the next are the clearance between tube and bending die Cb, the clearance between tube and mandrel Cm and the friction coefficient between tube and bending die fb, while the friction coefficient between tube and mandrel fm is the least one for springback. The reason is that the maximum range of the effect of e on springback angel/radius is (4.55°–7.70°)/(0.73–1.67 mm), and the maximum range difference value is 3.15°/0.94 mm, while that of fm is (6.27°–7.36°)/(1.16–1.46 mm), and the maximum range difference value is 1.09°/0.3 mm, the others are between the e and the fm as shown in Figure 6; therefore, the e exhibits the highest sensitivity to the springback behavior while the fm shows the lowest one.
Effect of springback on cross section deformation
Figure 10(a) shows the effect of springback on cross section deformation with different clearances between tube and mandrel Cm. It is found that the cross section deformation degree increases with the increasing of the Cm before and after springback. The tendency of the cross section deformation is changed under the same Cm before and after springback, and the cross section deformation appears a platform deforming characteristics after springback in middle zone. On the numerical value, the difference of the cross section deformation degree is very significantly under the same Cm before and after springback. It is known that the cross section deformation is induced by the resultant force of the axial tensile force in the outer tube. During the unloading, the axial tensile force is released sharply and thus the cross section deformation degree can be relieved. The calculation shows that the relative difference except a few points is within 30% before and after springback, while that of the most measurement section is more than 50% and some even more than 70%, namely, the springback has a great influence on the cross section deformation under different Cm.

Effect of springback on cross section deformation with different process parameters: (a) Cm, (b) Cb, (c) fm, (d) fb and (e) e.
Figure 10(b) shows the effect of springback on cross section deformation with different clearances between tube and bending die Cb. It is found that the cross section deformation degree increases with the increasing of the Cb before springback, while the variation of the Cb hardly affects the cross section deformation degree after springback. There is an obvious alleviation of the cross section deformation after springback and a platform deforming characteristics of cross section deformation is also shown after springback. The calculation shows that the cross section deformation degree after springback decreases 25% more than that before springback for all case with different Cb, and the relative difference of the most measurement section is more than 50%, namely, the springback also has a great influence on the cross section deformation under different Cb.
Figure 10(c) shows the effect of springback on cross section deformation with different friction coefficients between tube and mandrel fm. It is found that the cross section deformation degree increases with the increasing of the fm before and after springback, and the variation tendency of the cross section deformation after springback is similar to that before springback under the same fm, while the value of the cross section deformation degree is reduced after springback. The relative difference of the cross section deformation degree is more than 20% with different fm before and after springback, and that of most measurement section is more than 30%, namely, the springback also has a great influence on the cross section deformation under different fm.
Figure 10(d) shows the effect of springback on cross section deformation with different friction coefficients between tube and bending die fb. It is found that the cross section deformation decreases with the increasing of the fb before and after springback, but is not obvious. The tendency of the cross section deformation is changed after springback on the same fb, and a platform deforming characteristics is also appeared after springback. The springback of the cross section deformation is more serious near the pressure die end. The calculation shows that the relative difference of the cross section deformation is more than 25% for all case with different fb before and after springback, and that of most measurement section is more than 40%. Namely, the springback has a significant impact on the cross section deformation under different fb.
Figure 10(e) shows the effect of springback on cross section deformation with different mandrel extension length e. It is found that the cross section deformation degree decreases with the increasing of the e before and after springback. The variation tendency of cross section deformation after springback is similar to that before springback under the same e, while the cross section deformation degree decreases after springback. The cross section deformation degree decreases 20% more than that before springback for the most measurement section with different e. Namely, the springback also has a significant impact on the cross section deformation under different e.
Conclusion
Springback increases with the increasing of the clearance between tube and mandrel, the friction coefficient between tube and mandrel, the friction coefficient between tube and bending die, or with the decreasing of the mandrel extension length, while the springback first increases and then remains little changed with the increasing of the clearance between tube and bending die.
The sensitivity of springback radius to process parameters is larger than that of springback angle for 21-6-9 HSSST in NC bending. And the sensitivity of springback to process parameters from high to low are the mandrel extension length, the clearance between tube and bending die, the clearance between tube and mandrel, the friction coefficient between tube and bending die and the friction coefficient between tube and mandrel.
The variation rules of the cross section deformation after springback with different clearance between tube and mandrel, clearance between tube and bending die, friction coefficient between tube and mandrel, friction coefficient between tube and bending die and mandrel extension length are similar to that before springback. But under same process parameters, the relative difference of the most measurement section is more than 20% and some even more than 70% before and after springback, and a platform deforming characteristics of the cross section deformation is shown after springback.
Footnotes
Acknowledgements
The authors would like to thank the National Natural Science Foundation of China (No. 51164030) and the Key Project of Natural Science Research of Jiangxi Science & Technology Normal University (No. 300098010501) for the support given to this research.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship and/or publication of this article.
Funding
The author(s) received no financial support for the research, authorship and/or publication of this article.
