Round tube allows metal to flow evenly in all directions during the bend which makes it easier to control distortion. This makes the square tube more susceptible to distortion. In square tubing the entire tube wall is parallel to this plane and so is exposed to the tensile and compressive stress at the outside and inside of the bend. The plane of highest tension or compression is tangent to the cross section so it is less prone to distortion. Round tubing has less material in the most highly stressed regions. In tube bending you can bend round or square tubing. If the ultimate compressive strength of the material is reached, the tube will experience localized buckling resulting in rippling of the inside bend surface. The wall thickness on the inside of the tube bend will thicken due to compressive stresses. If the ultimate tensile stress of the material is surpassed, then the tube will rip along the outer bend surface. Wall thickness on the outside cross section of the bend will thin-out due to tensile stresses, because the outer wall tends to be pulled in toward the centerline or neutral axis of the part. ![]() When a metal tube is bent, the cross section material fibers experience tension on the outside of the bend area and compression on the inside of the bend area.
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