Development of a novel method of tube bending using finite element simulation

A novel tube bending method has been developed to form an elbow section from a straight tube using internal pressure and a rigid die. The process uses the rigid die to guide the tube into the elbow when pushed by a punch and internal pressure is used to prevent wrinkling and buckling. This paper presents the results from the finite element simulation process that was used to validate the concept and the design. A comparison between using internal hydraulic pressure via a liquid and using a urethane rod to supply the internal pressure was undertaken and the results are presented here.