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1、 1 AS 2505.22004 Standards Australia Australian Standard TM Metallic materials Method 2: Bars, rods and solid shapesBend tests PREFACE This Standard was prepared by Standards Australia Committee MT-006, Mechanical Testing of Metals to supersede AS 2505.21989, Methods for bend and related testing of
2、metals, Method 2: Bars, rods and solid shapes. The objective of this revision is to introduce new testing and reporting requirements for bend tests for bars, rods and solid shapes. This Standard is Method 2 of a series of Standards on the methods of bending wire and related testing of metals. The se
3、ries comprises the following Methods: AS 2505 Metallic materials 2505.1 Method 1: Sheet, strip and plateBend tests 2505.2 Method 2: Bars, rods and solid shapesBend tests (this Method) 2505.3 Method 3: Tubular productsBend and related tests 2505.4 Method 4: WireReverse bend test 2505.5 Method 5: Wire
4、Simple torsion test 2505.6 Method 6: WireWrapping test This Standard does not cover bend testing of welds, which is dealt with in the series of Standards, AS 2205, Methods of destructive testing of welds in metals. METHOD 1 SCOPE This Standard specifies methods for simple and reverse bend testing in
5、 the longitudinal direction of coated and uncoated metal bars, rods and solid shapes. NOTES: 1 Criteria for assessment of the results of tests are not included; they are specified in appropriate product Standards. 2 Where angles of bend of test pieces are specified in product Standards, they are dee
6、med to be minimum angles. However, where radii of bends of mandrels or formers are specified, they are deemed to be maximum radii. 2 DEFINITIONS For the purpose of this Standard, the definitions below apply. AS 2505.22004 Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 AS 2505.22004 2 Stand
7、ards Australia .au 2.1 Longitudinal bend test piece A test piece in which the length is parallel to, and the axis of the bend at right-angles to, the principal direction of extension during manufacture (see Figure 1). 2.2 Reverse bend test A test in which a test piece is deformed by bending through
8、90 degrees, over a specified radius and is then straightened. NOTE: To complete one reverse bend, the test piece is bent through 90 degrees and then straightened. To complete two reverse bends, the test piece is then bent through 90 degrees in the opposite direction and then straightened (see Figure
9、 2). 2.3 Simple bend test A test in which a test piece is deformed by bending through a specified angle, without reversing the direction of flexure. 2.4 Test sample A portion of metal or product or a group of items selected from a batch by a sampling procedure. 2.5 Test specimen A portion or a singl
10、e item taken from each product in the test sample for the purpose of applying a particular test. 2.6 Test piece A piece taken from each test specimen, and suitably prepared for testing. 3 NOTATION The quantity symbols used in this Standard are listed below. a = thickness or diameter of test piece in
11、 millimetres D = diameter of mandrel in millimetres F = Force in newtons Nb = number of reverse bends R = radius of supports in millimetres = angle of bend, in degrees NOTE: Except where test pieces are machined, a will be the original metal thickness or diameter. 4 APPARATUS The test apparatus shal
12、l be of such construction that test pieces can be appropriately controlled during the performance of the test, and be of adequate design, manufacture and materials to ensure reproducibility of results. The required apparatus is as shown in Figures 4, 5, 6, 7, 8, and 10, as appropriate to the specifi
13、c test methods. All support surfaces and mandrels shall be wider than the test piece. 5 TEMPERATURE OF TEST PIECE The temperature of test pieces at the beginning of a test shall be room temperature which, unless otherwise specified in the product Standard, shall be between 10C and 35C. In the event
14、of dispute, the temperature of test pieces at the beginning of a test shall be 23 5C. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 3 AS 2505.22004 .au Standards Australia 6 SELECTION AND PREPARATION OF TEST PIECE 6.1 General Test samples shall be selected and prepared for testing as spec
15、ified in the appropriate product Standard or the appropriate clauses of this Standard, as applicable. NOTE: Where the selection and preparation of test samples are not adequately specified by either the product Standard or this Standard, alternative methods may be selected. 6.2 Selection of test pie
16、ce If the position of the test piece in relation to the original bar, rod or solid shape from which it was taken is known, the test piece shall be prepared with its centre as near as practicable to the position indicated in Figure 3 for the relevant cross section type. NOTE: When an angle bar has le
17、gs of different sizes, the test sample may be taken from either leg. 6.3 Preparation of test piece Test pieces may be full section, stamped, sheared, sawn, flame-cut, machined, or any combination of these. If necessary, they may be straightened, provided that any distortion or heating does not signi
18、ficantly affect the test result. For test pieces that are not of full product cross-section there shall be no burrs, scratches or marks which can adversely affect the result. Unless otherwise specified in the product Standard, the edges of rectangular test pieces may be rounded to a radius as follow
19、s: (a) For thickness up to 10 mm. not greater than 1.0 mm. (b) For thicknesses above 10 mm. 0.1 times the thickness but not greater than 3 mm. Slight curvature of the test piece is acceptable. If the test piece is produced by machining a single surface of the product (see Clause 6.4.2(b), a simple b
20、end test shall be carried out with the unmachined surface in tension. In a reverse bend test, the unmachined side shall be in tension in the first bend of the test. In the event of dispute, any effect produced by the method of preparation on the metal structure along a cut edge shall be removed by l
21、ongitudinal milling) planing or grinding, unless otherwise specified in the product Standard. NOTE: Arrow indicates principal direction of extension during manufacture. FIGURE 1 LONGITUDINAL BEND TEST Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 AS 2505.22004 4 Standards Australia .au St
22、art position Position of test piece at completion of one reverse bend Position of test piece at completion of two reverse bends FIGURE 2 METHOD OF COUNTING REVERE BENDS 1/4 2/31/3 1/4 1/2 1/2 1/2 1/2 1/4 1/4 1/4 1/4 1/32/3 FIGURE 3 POSITION OF TEST PIECES 6.4 Dimensions 6.4.1 Length of test pieces T
23、he length of test piece shall be suitable for the test method selected. 6.4.2 Width of test piece Width of the test piece shall be in accordance with the following: (a) Flats and solid shapes Test pieces shall have the following widths, as appropriate to the thickness of the product being tested: (i
24、) For product thickness of less than 3.0 mm, test pieces shall be of rectangular cross section and of full product thickness. The width of the test pieces shall not be less than 20 mm, or not less than the full product width if this is less than 20 mm wide. Accessed by UNIVERSITY OF SOUTH AUSTRALIA
25、on 27 Feb 2007 5 AS 2505.22004 .au Standards Australia (ii) For product thickness of 3.0 mm up to and including 25 mm, test pieces shall be of rectangular cross-section and of full product thickness. The width of the test pieces shall not be less than 30 mm, or not less than the full product width i
26、f this is less than 30 mm wide. (iii) For product thickness above 25 mm, unless otherwise specified in the product Standard, test pieces may be machined to a thickness of not less than 25 mm, but shall be not less than 30 mm wide (unless precluded by product dimensions). Machining shall be restricte
27、d to one surface only. (b) Rods and bars not of rectangular cross-section Test pieces shall be prepared in accordance with the following, as appropriate to the cross-section of the product being tested: (i) For product thickness up to 25 mm (ii) For product thickness above 25 mm (distance across fla
28、ts or diameter), unless otherwise specified in the product Standard, test pieces may be machined to a thickness of not less than 25 mm, and shall be not less than 30 mm wide (unless precluded by product dimensions). Machining shall be restricted to one surface only. 7 SIMPLE BEND TEST PROCEDURES 7.1
29、 Simple bend 7.1.1 Application The procedure is suitable for bending metal of all thicknesses through angles up to a nominal 180 degrees. 7.1.2 Procedure The simple bend test shall be carried out as follows: (a) Place the test piece on two parallel supports; the radius, R, of the supports shall be n
30、ot less than 10 mm. Figure 4 illustrates the apparatus and test piece location for a simple bend test. Figure 5 illustrates a modified simple bend test using roller supports. The distance between supports for a nominal 180 degree bend shall be equal to (D + 3a) a/2. (b) Apply force through the mandr
31、el at a point mid way between the supports. The diameter of the mandrel shall be as specified in the product Standard. (c) Increase the force slowly until the test piece is bent through the specified angle , while the force is still applied. (d) Remove the force and examine the external bent portion
32、 of the test piece for cracks, or as required by the product Standard. NOTE: Small cracks at the edges of test pieces and cracks which require magnification to be visible may be disregarded, unless the product Standard indicates otherwise. 7.2 Vee-block bend 7.2.1 Application The procedure is suitab
33、le for bending test pieces of all thicknesses through angles up to a nominal 90 degrees. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 AS 2505.22004 6 Standards Australia .au 7.2.2 Procedure The Vee-block bend test shall be carried out as follows: (a) Place the test piece across a Vee-blo
34、ck which has an included angle as specified in the product Standard. (b) Apply a force through a mandrel at the midpoint of the Vee-block until the test piece is just stopped by the block (see Figure 6). The diameter of the mandrel shall be as specified in the product Standard. (c) Remove the force,
35、 and examine the external bent portion of the test piece for cracks, or as required by the product Standard. NOTE: Small cracks at the edges of test pieces, and cracks which require magnification to be visible, may be disregarded unless the product Standard indicates otherwise. F R10 mm min. Support
36、 Mandrel Support D/2 Test piece (D + 3a) a/2 a NOTE: Roller supports may be used (see Figure 5) where the distance between the supports is within the limits of (D + 3a) a/2 (see Clause 7.1.2(a). FIGURE 4 SIMPLE BEND TEST F R10 mm min. Mandrel D/2 Test piece Roller support Roller support (D + 3a) a/2
37、 a FIGURE 5 MODIFICATION OF SIMPLE BEND TEST USING ROLLER SUPPORTS Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 7 AS 2505.22004 .au Standards Australia F Mandrel D/2 R10 mm min. Test piece a FIGURE 6 VEE-BLOCK BEND TEST 7.3 Supported mandrel bend 7.3.1 Application The procedure is suitab
38、le for bending test pieces of all thickness through angles up to a nominal 180 degrees (see Figures 7 and 8). A limitation may arise in the testing of thin metal where a specified radius for the mandrel is less than that which would allow the roller pivot mechanism to be constructed within the mandr
39、el. In such cases use an external pivot design. 7.3.2 Procedure The supported mandrel bend test shall be carried out as follows: (a) Clamp one end of the test piece and the mandrel in a suitable vice. The diameter of the mandrel shall be as specified in the product Standard. (b) Apply a force to the
40、 end of the test piece and at right-angles so as to bend the test piece around the mandrel to the specified angle. The force may be applied manually, by blows from a soft mallet or by use of a roller bending device. Where a roller bending device is used, the distance from the point of contact of the
41、 roller to the mandrel shall not exceed 2a (see Figure 8). (c) Remove the test piece, and examine the external bent portion for cracks, or as required by the product Standard. NOTE: Small cracks at the edges of test pieces, and cracks which require magnification to be visible, may be disregarded unl
42、ess the product Standard indicates otherwise. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 AS 2505.22004 8 Standards Australia .au F Test piece Mandrel FIGURE 7 SUPPORTED MANDREL BEND TEST SIMPLE BEND TEST AROUND A MANDREL ViceTest piece Test piece Mandrel Roller Roller TOP VIEW FRONT VI
43、EW Vice Packing Vice Mandrel 2a max F a FIGURE 8 SUPPORTED MANDREL BEND TESTSIMPLE BEND TEST AROUND A MANDREL INCORPORATING A ROLLER BENDING DEVICE 7.4 Pressure bend 7.4.1 Application The method is suitable for bending test pieces of all thickness through various angles of bend commencing from nomin
44、al angles of more than 90 degrees. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 27 Feb 2007 9 AS 2505.22004 .au Standards Australia 7.4.2 Procedure The pressure bend test shall be carried out as follows: (a) Take a test piece and bend through an angle of more than 90 degrees, by one of the preceding
45、 methods described in this Standard. The diameter of the mandrel used shall be as specified in the product Standard. (b) Apply a compressive force until one of the following conditions, as specified in the product Standard, is attained: (i) The arms of the test piece are at a specified angle (see Fi
46、gure 9(a). (ii) The arms of the test piece are parallel to each other, and at a given distance apart (see Figure 9(b) and (c). The thickness of the spacer, where used, shall be as specified in the product Standard. (iii) The arms of the test piece are in direct contact with each other (see Figure 9(
47、d). (c) Remove the test piece and examine the external bend portion for cracks, or as required by the product Standard. NOTE: Small cracks at the edges of test pieces, and cracks which require magnification to be visible, may be disregarded unless the product Standard indicates otherwise. 8 REVERSE
48、BEND TEST PROCEDURE 8.1 Application The procedure is suitable for the testing of test pieces of all thicknesses. 8.2 Procedure The reverse bend test shall be carried out as follows: (a) Select appropriate supports having a radius as specified in the product Standard. (b) Insert the test piece in the
49、 bend test apparatus and clamp tightly (see Figure 10). NOTE: Tensile pre-stressing of thin test pieces to ensure close contact with the supports may be required if specified in the product Standard. (c) Apply a force to bend the test piece through 90 degrees, and then to return it to its start position (see Figure 1). (d) Repeat bending thro