Analysis of Asymmetric Plastic Bending Deformation of Welded Tube Sheets and Derivation of a Damage Law for J Shape-C Shape -O Shape Forming

The J shape-C shape -O shape (JCO) forming method of sheets for large-diameter longitudinally welded pipes has been widely used to manufacture oil and gas pipelines. The quality of welded pipes formed through the JCO process is directly affected by the accurate control of asymmetric bending springback and damage during the procedure. A finite element model (FEM) for JCO asymmetric bending was constructed to investigate the characteristics of asymmetric plastic bending deformation and the distribution laws of damage in JCO forming. This model was based on a nonlinear mixed hardening Lemaitre damage model coupled with the Quasi-Plastic-Elastic (QPE) model. Then, residual stress, forming shape, and damage degree of crimping, first bending, second bending, and third bending were analyzed. Moreover, the accuracy of the model was experimentally verified. Results demonstrate that, the asymmetric bending deformation process can be divided into five stages, including rigid body rotation phase, full elastic deformation phase, elastic–plastic uncladded deformation phase, elastic–plastic cladded phase, and springback phase. In the first bending, the stress centerline significantly misaligns with the mold centerline. Asymmetry is not evident in the second and third bending stages. Furthermore, the peak residual stress and peak damage can be effectively reduced by a larger punch radius, while the peak damage can be reduced by a larger die span. This study lays a foundation for optimizing the technical parameters of JCO forming. Keywords: JCO forming, asymmetric bending, finite element, QPE model, deformation characteristics