Diploma thesis discusses and summarizes the problematic how ovality effects durability of bended tubes. The work presents an approach to the solution, the experiments concerning change of ovality, changes in the thickness of the distorted cross-section. Final results represent connection between ovality and durability.

Master thesis analyzes rotary draw bending of the tubes without using a mandrel. Bending process is accompanied by many defects due to large displacement of formed material. One of the major defects is flattering of the cross section also called ovality. In order to decrease ovality comes up a proposal of the changes to the tool design. Modifications of tool’s geometry are numerically analyzed by finite element method in software ANSYS. According to the results of the simulations an optimized pressure die is manufactured. Several experimental tests are accomplished to verify the effect of the optimized tool design. Approximately 100 bends confirm a decrease of ovality using modified pressure die.

In several practical applications, hot-finished steel pipe that exhibits Lüders bands is bent to strains of 2-3%. Lüders banding is a material instability that leads to inhomogeneous plastic deformation in the range of 1-4%. This work investigates the influence of Lüders banding on the inelastic response and stability of tubes under rotation controlled pure bending. It starts with the results of an experimental study involving tubes of several diameter-to-thickness ratios in the range of 33.2 to 14.7 and Lüders strains of 1.8% to 2.7%. In all cases, the initial elastic regime terminates at a local moment maximum and the local nucleation of narrow angled Lüders bands of higher strain on the tension and compression sides of the tube. As the rotation continues, the bands multiply and spread axially causing the affected zone to bend to a higher curvature while the rest of the tube is still at the curvature corresponding to the initial moment maximum. With further rotation of the ends, the higher curvature zone(s) gradually spreads while the moment remains essentially unchanged. For relatively low D/t tubes and/or short Lüders strains, the whole tube eventually is deformed to the higher curvature entering the usual hardening regime. Subsequently it continues to deform uniformly until the usual limit moment instability is reached. For high D/t tubes and/or materials with longer Lüders strains, the propagation of the larger curvature is interrupted by collapse when a critical length is Lüders deformed leaving behind part of the structure essentially undeformed. The higher the D/t and/or the longer the Lüders strain is, the shorter the critical length. This class of problems is analyzed using 3D finite elements while the material is modeled as an elastic-plastic solid with an “up-down-up” response over the extent of the Lüders strain, followed by hardening. The analysis reproduces the main features of the mechanical behavior provided the unstable part of the response is suitably calibrated. The uniform curvature elastic regime terminates with the nucleation of localized banded deformation. The bands appear in pockets on the most deformed sites of the tube and propagate into the hitherto intact part of the structure while the moment remains essentially unchanged. The Lüders-deformed section has a higher curvature, ovalizes more than the rest of the tube, and develops wrinkles with a characteristic wavelength. For every tube D/t there exists a threshold of Lüders strain separating the two types of behavior. This bounding value of Lüders strain was studied parametrically. / text

One of the important parameters observed during extruded fibre fabrication is its diameter. The diameter can be measured with a single scanning camera assuming that the fibre section has a circular shape. As proved in practice, another important parameter is ovality, that is the rate of fibre flattening. This paper assumes that the fibre section shape is elliptical. In such a case, at least three different views on examined fibre are needed. Mathematical part of this paper is concerned with analytical description of fibre ovality measurement using two different approaches based on the knowledge of linear algebra, projective geometry and conic sections theory. Main goal of this paper is thus to use both mathematical theory and image analysis methods for ovality and diameter determination. Precise calcluation of such quantities is, however, conditioned on precise camera system calibration, which is described in the paper as well. Additionally, the work contains a brief mention of technical realization of ovality measurement and its possible difficulties.