Analysis of Residual Stresses in Bending and Forming of Aerospace Titanium Alloy Tubes Influenced by Temperature Variations

Titanium alloy bent tubes are extensively utilized in the aerospace industry, with thermal bending being a commonly employed fabrication method in recent years. This study investigates the residual stress in thin-walled titanium alloy tubes after bending. Through theoretical modeling, numerical simulations, and experimental analysis, the residual stress distribution and magnitude post bending in aerospace-grade titanium alloy tubes are examined. Initially, an analytical model for residual stress in titanium alloy tubes post bending unloading is established, followed by the creation of a three-dimensional thermal bending model using the finite element method. Subsequently, by theoretically calculating and simulating the temperature and stress field variations during the warm bending process of titanium alloy, the residual stress distribution and numerical solutions post bending are determined. Finally, experimental validation of the numerical simulation results is conducted using a stress tester, yielding good agreement between experimental and numerical simulation outcomes. The aim of this research is to provide a comprehensive theoretical understanding and solution for the residual stress issue in the thermal bending of titanium alloy aerospace tubes, thereby promoting scientific development and technological advancement in related fields.