Theoretical modelling and finite element simulation of AA6061 involute components based on 3D free bending process

In this study, theoretical modelling and finite element simulations were performed to reveal the forming mechanics of involute components based on a 3D free bending process. During forming the involute components, as the bending radius increased, the equivalent stress, the tangential strain, and the ellipticity of the cross-section were gradually decreased. Furthermore, the compressive stresses located inside the components were greater than the tensile stresses located outside them; thus, the thickening inside the involute components were greater than the thinning outside them. In addition, under the same bending radius, the equivalent stress and tangential strain of the spatial involute components were larger than those of the plane involute. Therefore, the thickening proportion of the inner wall, and the thinning proportion of the outer wall of the spatial involute components were greater than those of the plane involute. The cross-section ellipticity of the spatial involute components were smaller than that of the plane involute components. The results acquired from the theoretical modelling are in line with those obtained from finite element simulation and experimentation.