Finite element analysis of tube drawing process with diameter expansion

This paper presents a tube drawing process with diameter expansion for producing a thin-walled tube effectively. In this proposed process, the tube was flared by a plug pushing into the tube, and then the tube was expanded by drawing the plug in the tube axial direction with chucking the flared tube edge. Optimum plug shape, such as the plug half angle and the corner radius, was investigated by a series of analyses using the finite element method (FEM) for improving the forming limit and the dimension accuracy. At first, a friction coefficient was determined to 0.3 by a comparison of the flaring limit between the analysis and the experiment of the tube flaring. As a result of the analyses in the drawing with the diameter expansion, the forming limit was high when the plug half angle was set to 18~30°. The thickness reduction ratio increased with an increase in the expansion ratio and the plug half angle. In addition, the overshoot, which is a difference between the plug diameter and the tube inner diameter after the drawing, was prevented by using the plug with the corner radius of 20 mm.