Study of Aluminum Tube Cold Nosing Process Into Conical and Hemispherical Dies

Abstract

Theoretical analysis and finite element method were used to simulate the cold nosing process of commercial purity Aluminum tubes into conical and hemispherical dies. The influences of process parameters, namely initial tube wall thickness, conical semi-die angle and coefficient of friction were investigated. The results of the nosing process were obtained in terms of load-displacement curves, thickness distribution of deformed parts, the nosing ratios and strain distributions. According to these finding, the final shape and defects of the product can also be predicted. Experimental work was carried out to verify the simulation results. A new developed setup design was proposed to improve the product quality. Two adjacent punches were used: one with a front plunger and the other was an outer sleeve to constrain the tube. It could be observed that the load increase with increasing the tube wall thickness, semi die angle and coefficient of friction. The nosing ratio increases as wall thickness increases. Comparison between analytical and FE predictions to the experimental results showed good agreement.

Finite Element Simulation and Experimental Verification of Circular Tube Nosing through Conical Dies

“…An approximate theory was developed that combines the volume incompressible condition and the Levy-Mises equation to calculate preform shape, nosing ratio, and loading rate in the tube nosing process by spherical die [18]. Lastly, finite element method analysis was used for the tapered die eccentric necking process to investigate the effects of process parameters, such as the initial tube wall thickness, semi-die angle, and friction coefficient [19,20]. The process of double-nosing in tubes was scrutinized.…”