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Formability Limits in Square Tubes and L-Section Profiles.

Inês M Almeida¹, João P G Magrinho¹, Maria Beatriz Silva¹

¹IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal.

Materials (Basel, Switzerland)

|June 27, 2025

Summary

This summary is machine-generated.

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This study introduces a new method to measure the formability limits of square and L-section tubes. The findings improve manufacturing efficiency and structural reliability for lightweight components.

Area of Science:

Materials Science and Engineering
Mechanical Engineering
Manufacturing Processes

Background:

Thin-walled tubes with non-circular cross-sections (square, L-section) are vital in automotive and aerospace.
Their formability limits and fracture behaviors differ significantly from circular tubes, requiring specialized analysis.
Existing research often overlooks these specific geometries, creating a knowledge gap in manufacturing optimization.

Purpose of the Study:

To develop and validate a novel methodology for accurately determining the formability limits of square and L-section tubes.
To investigate the unique deformation and fracture mechanisms in these profiles under various forming conditions.
To provide critical data for optimizing manufacturing processes and enhancing the structural integrity of components made from these tubes.

Keywords:

L-profiles formability limits fracture necking thin-walled tubes

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Main Methods:

Implementation of digital image correlation (DIC) combined with a time-dependent approach for precise strain measurement.
Inclusion of accurate thickness measurements to capture localized deformation accurately.
Conducting experimental tests under controlled forming conditions to capture diverse strain paths leading to failure.

Main Results:

Successful identification of forming limit points (onset of necking) and fracture forming lines (crack initiation).
Characterization of fracture mechanisms influenced by specific tube geometries (square, L-section).
Distinction between fracture modes: tension (Mode I) and in-plane shear (Mode II).

Conclusions:

The developed methodology accurately quantifies formability limits for non-circular tubes.
Geometric factors significantly influence fracture mechanisms in square and L-section profiles.
The study provides essential data for optimizing tube forming processes, enhancing component design and performance.