【AS澳大利亚标准】AS 2505-3-2004 Metallic materials Method 3 Tubular products—Bend and related tests.doc

australian standardtm1 as 2505.32004accessed by university of south australia on 02 mar 2007as 2505.32004metallic materialsmethod 3: tubular productsbend and related testsprefacethis standard was prepared by standards australia committee mt-006, mechanical testing of metals to supersede as 2503.31989, methods for bend and related testing of metals, method 3: tubular products.the objective of this revision is to revise the testing procedure to allow a wider variation in sizes.this standard is a method 3 of a series of standards on the methods of bending wire and related testing of metals. the series comprises the following methods:as2505metallic materials2505.1method 1:sheet, strip and platebend tests2505.2method 2:bars, rods and solid shapesbend tests2405.3method 3:tubular productsbend and related tests (this standard)2405.4method 4:wirereverse bend test2505.5method 5:wiresimple torsion test2505.6method 6:wirewrapping testmethod1 scopethis standard specifies four test methods for determining the resistance of metallic seamless and welded tubes to plastic deformation.note: criteria for assessment of results of tests are not included; they are set out in appropriate product standards.2 definitionsfor the purpose of this standard, the definitions below apply.2.1 test samplea portion of metal or product, or items selected from a batch or group by a sampling procedure.2.2 test specimena portion, or a single item, taken from a test sample for the purpose of applying a particular test. standards australiaas 2505.320047accessed by university of south australia on 02 mar 20072.3 test piecea piece taken from each test specimen, and suitably prepared for testing.3 notationthe quantity symbols used in this standard are listed below.a = wall thickness of tube, in millimetresd= original external diameter of tube, in millimetresdu= ultimate external diameter after testing, in millimetresh= distance between platens, in millimetresl= length of test piece, in millimetresr= radius of the flange, in millimetresr = internal radius of bend, in millimetres = angle of bend, in degrees = conical angle of the mandrel, in degrees4 apparatusthe test apparatus shall be of such construction that test pieces can be appropriately controlled during the performance of the test, and be of adequate design to ensure reproducibility of results. the required apparatus is shown in figures 1, 2, 3 and 4 as appropriate to the specific test methods.all mandrels and drift surfaces shall have an n4 finish (ra = 0.2 m) or smoother, and a surface hardness of 600 hv minimum.5 temperature of test piecethe temperature of the test piece at the beginning of the test shall be room temperature which, unless otherwise specified in the product standard, shall be between 10c and 35c.in the event of dispute, the temperature of the test piece at the beginning of the test shall be23 5c.6 bend test (full section)6.1 test piece selection and preparationthe test piece shall be selected and prepared for testing as specified in the relevant product standard. if not specified, the test piece shall be taken from a portion of straight tube, and be of length suitable for the test to be carried out in the bending machine.6.2 test procedurethe full-section bend test shall be carried out as follows:(a) insert the test piece in the bend test machine using a grooved former of specified radius (see figure 1).where welded tubes are being tested, position the weld in relation to the plane of bending as specified in the product standard.where not specified in the product standard, place the weld at 45 degrees to the contact line at the start of the test.(b) bend the tube until the angle of bend reaches the value specified in the productstandard.(c) remove the force and examine the external bent portion of the test piece for cracks, or as required by the product s.au standards australiaaccessed by university of south australia on 02 mar 20076.3 interpretationcracks which require magnification to render them visible shall be disregarded, unless the product standard specifies otherwise.figure 1 bend test (full section)7 flattening test7.1 test piece selection and preparationthe test piece shall be selected and prepared for testing as specified in the appropriate product standard.where the test piece is cut from the tube, its length shall be 1.5 times the external diameter of the tube, but not less than 40 mm, nor more than 100 mm. the cut ends shall be at approximately right angles to the axis of the tube, and may be rounded by filing.note: a test on a test piece whose edges have not been rounded should be accepted, provided the requirements of the product standard are satisfied.7.2 procedurethe flattening test shall be carried out as follows:(a) position the test piece in between two parallel rigid platens (see figure 2).where welded tubes are being tested, position the weld as specified in the productstandard.where not specified in the product standard, place the weld at 90 degrees to the contact line at the start of the test (see figure 2(a).(b) flatten the test piece by moving the platens in a direction perpendicular to the longitudinal axis of the tube, until the distance between platens (h) reaches the value specified in the product standard (see figure 2(b).in the case of close flattening apply pressure until at least half of the width of the internal surface is in intimate contact (see figure 2(c).the rate of movement of the platens is not specified; however, in the event of dispute, the rate of closure of the platens shall not exceed 25 mm/min, measured under load in the direction of flattening.(c) remove the test piece and examine for cracks, or as required by the product standard.7.3 interpretationcracks which require magnification to be visible may be disregarded unless the productstandard specifies otherwise.accessed by university of south australia on 02 mar 2007figure 2 flattening testaccessed by university of south australia on 02 mar 20078 drift expansion test8.1 test piece selection and preparationthe test piece shall be selected and prepared for testing as specified in the appropriate product standard. if not specified, the test shall be made on a test piece having a length in accordance with the following, but not less than 50 mm (see note 1):for a conical angle of mandrel of less than 30 . 2d for a conical angle of mandrel of 30 or more . 1.5d where d = tube diameter, in millimetres.notes:1for tubes with a diameter of less than 25 mm, the test piece may be shorter than 50 mm, provided the remaining cylindrical part of the test piece, after expansion, is at least 0.5d.2the end to be tested should be in a plane perpendicular to the axis of the tube.3the edges of the end to be tested may be rounded by filing. however, a test on a test piece whose edges have not been rounded is acceptable, provided the result of the test meets the requirements of the product standard.8.2 procedurethe drift expansion test shall be carried out as follows:(a) position the test piece on a flat platen (see figure 3). locate the conical mandrel in position.(b) force the mandrel into the tube without shock until the external diameter du, reaches the value specified in the product standard.do not permit the test piece to rotate during the test and, if necessary, hold it mechanically to prevent rotation.the rate of penetration of the mandrel is not specified; however, in the event of dispute, the rate of penetration shall not exceed 50 mm/min.(c) remove the test piece and examine for cracks, or as required by the product standard.notes:1conical mandrels with included angles of 30 degrees, 45 degrees or 60 degrees are usually specified. mandrels with other included angles may be used, if specified in the product standard.2where testing welded tubes, the mandrel may be grooved to accommodate any internal weld flash.8.3 interpretationcracks which require magnification to render them visible shall be disregarded, unless the product standard specifies otherwise.accessed by university of south australia on 02 mar 2007figure 3 drift expansion test9 flanging test9.1 test piece selection and preparationthe test piece shall be selected and prepared for testing as specified in the appropriate product standard. if not specified, the length of the test piece, l shall be such that the remaining cylindrical part of the test piece after flanging is at least 0.5 times the external diameter of the tube.notes:1the end to be tested should be in a plane perpendicular to the axis of the tube.2the edges of the end to be tested may be rounded by filing. however, a test on a test piece whose edges have not been rounded is acceptable, provided the result of the test meets the requirements of the product standard.9.2 procedurethe flanging test shall be carried out as follows:(a) position the test piece on a flat platen. locate the conical mandrel in position (seefigure 4(a).(b) force the mandrel into the tube, without shock, until the external diameter, du, reaches the value specified in the product standard.(c) remove the conical mandrel and insert a suitably lubricated forming tool (seefigure 4(b), having(i) a cylindrical end, of diameter about 1 mm less than the inside diameter of the tube;(ii) a flat concentric portion perpendicular to the axis of the forming tool, and having a diameter not less than the required diameter of the flange; and(iii) a fillet joining the cylindrical end and the flat portion, the radius being such that the external radius of the flange is at least equal to that required.accessed by university of south australia on 02 mar 2007(d) apply pressure until the external diameter, du, and the flange radius, r, reach the value specified in the product standard.do not permit the test piece to rotate during the test and, if necessary, hold it mechanically to prevent rotation.the rate of penetration of the conical mandrel and the forming tool are not specified;however, in the event of dispute, the rate of penetration shall not exceed 50 mm/min.(e) remove the test piece, and examine for evidence of cracks or as required by the product standard.9.3 interpretationcracks which require magnification to render them visible shall be disregarded, unless the product standard specifies otherwise.figure 4 flanging test10 test reportthe test report shall include the following information: (a)the number of the product standard.(b) sample identity. (c)result of the test.(d) report number and date.if not specified in the product standard, the report shall also include, where relevant, the following information:(i) type of test.(ii) nominal dimensions of the test piece.(iii) the number of this australian standard, i.e. as 2505.3.as 2505.32004accessed by university of south australia on 02 mar 2007this australian standard was prepared by committee mt-006, mechanical testing of metals. it was approved on behalf of the council ofstandards australia on 27 september 2004 and published on 18 october 2004.the following are represented on committee mt-006: australian railway associationsbureau of steel manufacturers of australiacsiro national measurement laboratorycsiro telecommunications and industrial physicsinstitute of materials engineering australia limitednational association of testing authorities australiakeeping standards up-to-datestandards are living documents which reflect progress in science, technology and systems. to maintain their currency, all standards are periodically reviewed, and new editions are published. between editions, amendments may be issued. standards may also be withdrawn. it is important that readers assure themselves they are using a current standard, which should include any amendments which may have been published sinc