Precision metal forming; Cold tube drawing; Tube sinking; Mandrel drawing; Finite element method; Large deformation
Abstract :
[en] Cold tube drawing is a metal forming process that allows manufacturers to produce high-precision tubes. The dimensions of the tube are reduced by pulling it through a conical converging die with or without inner tool. In this study, finite element modelling has been used to give a better understanding of the process.
This paper presents a model that predicts the final dimensions of the tube with very high accuracy. It is validated thanks to experimental tests. Moreover, five studies are performed with this model, such as investigating the influence of the die angle on the drawing force or the influence of relative thickness on tube deformation.
Poncin, P., Ferrier, D., Loshakove, A., Proft, J., Meyer-Kobbe, C., A comparison between two manufacturing methods. Russell, A.P.S., (eds.) Proceedings of the International Conference on Shape Memory and Superelastic Technologies, Asilomar, California, May 2000, 2000, 477.
Amborn, U., Ghosh, S., Leadbetter, I., Modern side-shafts for passenger cars: manufacturing processes II – Monobloc tube shafts. J. Mater. Process. Technol. 63:1 (1997), 225–232, 10.1016/S0924-0136(96)02746-X.
Yoshida, K., Furuya, H., Mandrel drawing and plug drawing of shape-memory-alloy fine tubes used in catheters and stents. J. Mater. Process. Technol. 153 (2004), 145–150, 10.1016/j.jmatprotec.2004.04.182.
Palengat, M., Modélisation des couplages multiphysiques matériaux–produits–procédés lors de l'étirage de tubes : application aux alliages métalliques usuels. Ph.D. thesis, 2009, Université de Grenoble, France (in French).
Um, K.-K., Lee, D.N., An upper bound solution of tube drawing. J. Mater. Process. Technol. 63:1 (1997), 43–48, 10.1016/S0924-0136(96)02597-6.
Alexandrova, N., Analytical treatment of tube drawing with a mandrel. Proc. Inst. Mech. Eng., C J. Mech. Eng. Sci. 215:5 (2001), 581–589, 10.1243/0954406011520968.
Alexandrova, N., Fracture analysis of tube drawing with a mandrel. J. Mater. Process. Technol. 142:3 (2003), 755–761, 10.1016/S0924-0136(03)00618-6.
Zhao, D., Du, H., Wang, G., Liu, X., Wang, G., An analytical solution for tube sinking by strain rate vector inner-product integration. J. Mater. Process. Technol. 209:1 (2009), 408–415, 10.1016/j.jmatprotec.2008.02.011.
Sawamiphakdi, K., Lahoti, G., Kropp, P., Simulation of a tube drawing process by the finite element method. J. Mater. Process. Technol. 27:1 (1991), 179–190, 10.1016/0924-0136(91)90052-G.
Linardon, C., Favier, D., Chagnon, G., Gruez, B., A conical mandrel tube drawing test designed to assess failure criteria. J. Mater. Process. Technol. 214:2 (2014), 347–357, 10.1016/j.jmatprotec.2013.09.021.
Karnezis, P., Farrugia, D., Study of cold tube drawing by finite-element modelling. J. Mater. Process. Technol. 80 (1998), 690–694, 10.1016/S0924-0136(98)00127-7.
Palengat, M., Chagnon, G., Favier, D., Louche, H., Linardon, C., Plaideau, C., Cold drawing of 316L stainless steel thin-walled tubes: experiments and finite element analysis. Int. J. Mech. Sci. 70 (2013), 69–78, 10.1016/j.ijmecsci.2013.02.003.
Sheu, J.-J., Lin, S.-Y., Yu, C.-H., Optimum die design for single pass steel tube drawing with large strain deformation. Proc. Eng. 81 (2014), 688–693, 10.1016/j.proeng.2014.10.061.
Lee, S.-K., Jeong, M.-S., Kim, B.-M., Lee, S.-K., Lee, S.-B., Die shape design of tube drawing process using Fe analysis and optimization method. Int. J. Adv. Manuf. Technol. 66:1 (2013), 381–392, 10.1007/s00170-012-4332-8.
Béland, J.-F., Fafard, M., Rahem, A., D'Amours, G., Côté T., Optimization on the cold drawing process of 6063 aluminium tubes. Appl. Math. Model. 35:11 (2011), 5302–5313, 10.1016/j.apm.2011.04.025.
Kim, S., Kwon, Y., Lee, Y., Lee, J., Design of mandrel in tube drawing process for automotive steering input shaft. J. Mater. Process. Technol. 187 (2007), 182–186, 10.1016/j.jmatprotec.2006.11.134.
METAFOR website, University of Liège, Belgium, http://metafor.ltas.ulg.ac.be/.
Noels, L., Stainier, L., Ponthot, J.-P., Simulation of crashworthiness problems with improved contact algorithms for implicit time integration. Int. J. Impact Eng. 32:5 (2006), 799–825, 10.1016/j.ijimpeng.2005.04.010.
Adam, L., Ponthot, J.-P., Numerical simulation of viscoplastic and frictional heating during finite deformation of metal. Part I: theory. J. Eng. Mech. 128:11 (2002), 1215–1221, 10.1061/(ASCE)0733-9399(2002)128:11(1215).
ASTM F138-00: Standard Specification for Wrought 18 Chromium–14 Nickel–2.5 Molybdenum Stainless Steel Bar and Wire for Surgical Implants (UNS S31673), https://doi.org/10.1520/F0138-00.
Fréchard, S., Redjaïma, A., Metauer, G., Lach, E., Lichtenberger, A., Comportement dynamique et évolution microstructurale d'un acier inoxydable austénitique allié à l'azote. Matériaux 2002, Tours, France, 2002 (in French).
Johnson, G., Cook, W., A constitutive model and data for metals subjected to large strains, high strain rates, and high temperatures. Proceedings of the 7th International Symposium on Ballistics, The Hague, Netherlands, 19–21 April 1983, 1983, 541–547.
Joyot, P., Modélisation numérique et expérimentale de l'enlèvement de matière : application à la coupe orthogonale. Ph.D. thesis, 1994, Université Bordeaux-1, Bordeaux, France (in French).
Linardon, C., Precision Tube Drawing for Biomedical Applications: Theoritical, Numerical and Experimental Study. Ph.D. thesis, 2013, Université de Grenoble, France.
Sandru, N., Camenschi, G., A mathematical model of the theory of tube drawing with floating plug. Int. J. Eng. Sci. 26:6 (1988), 569–585, 10.1016/0020-7225(88)90055-9.
Chung, J., Hulbert, G., A time integration algorithm for structural dynamics with improved numerical dissipation: the generalized-α method. J. Appl. Mech. 60:2 (1993), 371–375, 10.1115/1.2900803.
