Bending is widely used for manufacturing of lightweight tubular parts and structures in many industrial clusters. In tube bending, springback is an important deformation behavior since it causes crucial problems related to the accuracy, quality, and properties of the bent tubular parts. This research presents a generalized analytical solution for springback in tube bending, enabling accurate and efficient analysis of springback for bending of general tubular materials, in particular, for the tubes with tension-compression asymmetry. Via comprehensively considering the critical parameters related to material, geometry, and process, the neutral layer shifting was analytically modeled for an accurate solution of stress/strain distributions in bending deformation. In tandem with this, by introducing the deformation history affected nonlinear degradation of elastic modulus and the dimensional change of tube section into the analysis of unloading process, an analytical springback model was established. By taking the rotary draw bending of high-strength titanium tubes as a case study, the developed analytical modelwas carefully evaluated, showing its good efficiency for springback prediction—particularly for the large-angle (≥ 90 deg.) forming cases with an average relative error below 5.79%. Based on the model, the effects of the critical parameters related to material, geometry, and process on neutral layer shifting, moment, and springback were thoroughly studied for a better understanding of the sensitivity of springback to these influential factors.

弯曲在许多产业集群中广泛用于制造轻型管状零件和结构。在弯管中，回弹是一种重要的变形行为，因为它会导致与弯管零件的精度、质量和性能相关的关键问题。本研究提出了管材弯曲回弹的通用分析解决方案，能够准确有效地分析一般管材弯曲的回弹，特别是对于具有拉压不对称性的管子。通过综合考虑与材料、几何形状和工艺相关的关键参数，对中性层位移进行分析建模，以准确解决弯曲变形中的应力/应变分布。与此同时，通过将变形历史影响弹性模量的非线性退化和管截面尺寸变化引入卸载过程分析，建立了解析回弹模型。以高强度钛管的旋转拉弯为例，对所开发的分析模型进行了仔细评估，显示其回弹预测效率高，尤其是对于大角度（≥ 90 度）成形情况，平均相对误差低于 5.79%。基于该模型，深入研究了与材料、几何形状和工艺相关的关键参数对中性层位移、力矩和回弹的影响，以更好地了解回弹对这些影响因素的敏感性。