Effect of mandrel on forming quality in sizing process of double-wall brazed tube

Qiao-Zhen Su; Hong Sun; Jun Ma; Meng-Meng Liu; Xuan-Cheng Hao; Yu-Li Liu; Heng Li

doi:10.1007/s40436-026-00600-4

Advances in Manufacturing ›› :1 -14. DOI: 10.1007/s40436-026-00600-4

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Effect of mandrel on forming quality in sizing process of double-wall brazed tube

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¹School of Materials Science and Engineering, Northwestern Polytechnical University, 710072, Xi’an, People’s Republic of China

², Xi’an Rare Metal Materials Institute Co. Ltd., 710072, Xi’an, People’s Republic of China

^a sunhong@nwpu.edu.cn

Qiao-Zhen Su

Qiao-Zhen Su is a Ph.D. candidate at School of Materials Science and Engineering, Northwestern Polytechnical University. Her research interests include the simulation of roll-forming and intelligent tube-bending systems based on machine learning.

Hong Sun

Hong Sun is a postdoctoral fellow at Northwestern Polytechnical University. Her research interests include precision plastic forming and simulation optimization of high-performance components，such as single/double tube bending and cryogenic forming.

Jun Ma

Jun Ma is a professor at Northwestern Polytechnical University. His research focuses on advanced metal forming, hybrid manufacturing, intelligent equipment, and sustainable manufacturing.

Meng-Meng Liu

Meng-Meng Liu is a Ph.D. at School of Materials Science and Engineering, Northwestern Polytechnical University. Her research interests include roll-forming of tubes and the deformation mechanism of materials.

Xuan-Cheng Hao

Xuan-Cheng Hao is a Ph.D. candidate at School of Materials Science and Engineering, Northwestern Polytechnical University. His research interests include the rolling and welding of welded tubes and multiscale simulation of material-forming processes.

Yu-Li Liu

Yu-Li Liu is a professor at Northwestern Polytechnical University. Her research interests include precision plastic forming and simulation optimization of advanced materials, including tube bending, roll forming, and stamping forming.

Heng Li

Heng Li is a professor at Northwestern Polytechnical University. His research interests include precision plastic forming and simulation optimization of high-performance components such as tube bending, creep aging forming for panel components with complicated structures, and high-efficiency forming of shape-memory alloy components.

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Abstract

The sizing process is a critical intermediate forming procedure in multipass rolling-brazing for producing double-wall brazed tubes (DWBTs). In the sizing process, the mandrel plays an essential role in accurately forming DWBTs and ensuring tight fitting of the inner and outer layers, which is of great importance for the success of the subsequent brazing operation, as well as the quality of the final product. However, achieving control over precise dimensions and uniform stress distribution in the formed tube remains a challenge. This study aims to obtain the optimal design parameters of an olive-shaped mandrel by investigating the effect of its key parameters, specifically the length and diameter of the mandrel head, on the forming quality of DWBTs during the sizing process. The results of experimental and numerical studies show that, with the increasing length and diameter of the mandrel head, the cross-section of the formed double-wall tube gets closer to an ideal roundness. An increase in the mandrel head length results in a more uniform stress distribution but a decreased uniformity in the wall thickness. In contrast, an increase in the mandrel head diameter improves the geometrical accuracy of the formed double-walled tube; however, the uniformity of the stress distribution decreases owing to the higher sizing force. Through a comprehensive analysis of multiple forming indices such as roundness, wall thickness distribution, and stress distribution, the optimal design parameters of the sizing mandrel are determined, offering practical guidance for achieving high-quality DWBT manufacturing.

Keywords

Double-wall brazed tube (DWBT) / Sizing process / Olive-shaped mandrel / Forming quality

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Qiao-Zhen Su, Hong Sun, Jun Ma, Meng-Meng Liu, Xuan-Cheng Hao, Yu-Li Liu, Heng Li. Effect of mandrel on forming quality in sizing process of double-wall brazed tube. Advances in Manufacturing 1-14 DOI:10.1007/s40436-026-00600-4

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