Finite element analysis of a tube swaging process

1) Graduate student of Gyeongsang National University(GNU), Jinju / Korea; 2) TIC of Gyeongsang National University; 3) Korea Institute of Industrial Technology, Incheon / Korea; #) School of Mechanical and Areospace Engineering, GNU, Jinju / Korea, msjoun@gnu.ac.kr

Korean Society for Technology of Plasticity

Mincheol Kim 1), Jaegun Eom 2) , Sungju Lim3), Hojun Choi3) , ManSoo Joun #

www.afdex.com

AFDEX

Contents

⊙ Research background

⊙ Analysis model

⊙ Condition of finite element analysis

⊙ History of deformation

⊙ Animation

⊙ Conclusions

⊙ Future plans

Research background

⊙ The advantage of swaging process

○ Various shapes as round, square, tapered shape of products, the swaging process is very

advantageous for mass production

○ Because equipments inexpensive and simple, easy to work with anyone that is unskilled

○ Because of chipless forming, material savings can be applied to large and non-ferrous materials

○ Available forming at cold and hot temperatures

Research background

⊙ Literature search

○ Piela, Grosman and Piela: assume 2-dimentional problem

Research background

⊙ Literature search

○ H.J.Jeong et. al., FEA

Prediction-DEFORMTM

Before After

Research background

⊙ Objective of research

○ The rigid-plastic finite element method is used.

○ Simulate a tube swaging process

Spindle head Control panel

4- Split die

Thicker shim plate

Equipment and dies of rotary swaging

Developed rotary swaging machine (RSM25)

Reference: Korea Institute of Industrial Technology

Equipment and dies of rotary swaging

Developed rotary swaging die

Design of swaging die Manufacture of swaging die

Reference: Korea Institute of Industrial Technology

Analysis model

Schematic diagram of a swaging process and Analysis model

Radial motion

of die

Radial motion

of die

Longitudinal motion

of workpiece

Longitudinal motion

of pusher

⊙ Forming speed [mm/rev.]

○ Workpiece longitudinal speed: mm/s ○ Spindle number of revolution: rpm

⊙ Reduction of area

Parameters Parameters Value

Tube:STKM11A Solid:S45C 25

Reduction of Reduction of 40

50

60

Ratio of t/d t/d Δd(%) Forming 0.5

Reduction of 1/10 15 speed 1.0

diameter(%) 1/20 30 (mm/rev.) 1.5

1/30 50 2.0

area(%)55diameter(%)

Value

30

45

Feed speed

(mm/min)

Spindle

revolution(rpm)200 200 200 200

Forming speed

(mm/rev)

100 200 300 400

0.5 1 1.5 2

(mm/min)(mm/rev) =

(rev/min)

Workpiece longitudinal Forming speed

Spindle number of revolution

Variation of forming process

Reference: Korea Institute of Industrial Technology

Distance [mm]

Lo

ad

[kN

]

0 5 10 15 20 25 300

5

10

15

20

25

30

⊙ Flow stress

⊙ Coefficient of Coulomb friction

⊙ Velocity

○ Velocity of radial motion of dies

○ Velocity of longitudinal motion of workpiece

○ Angular velocity of workpiece

⊙ Cycle time: 1.108s

⊙ Back pressing force exerted by the pusher

Conditions of finite element analysis

0.22712.8962 MPa

D

rv

M

lv

Mw

Time [s]

Ve

locity

[mm

/s]

an

gu

lar

ve

locity

[de

g/s

]

0 0.2 0.4 0.6 0.8 1-15

-10

-5

0

5

10

15

0

20

40

60

80D

rv

M

lv

Mw

Velocities of workpiece and dies with time

0.05

Back pressing force exerted by the pusher

with the movement of the back end of the

workpiece

History of deformation

Initial Blow. 10

Blow. 19 Blow. 28

Blow. 37 Blow. 46

Blow. 54 Blow. 67

⊙ Effective strain

LS-Dyna

Compare experiment with prediction

Wrinkle Thickness

Reference: Korea Institute of Industrial Technology

Animation

Conclusions

⊙ A scheme of analyzing a swaging process by finite element method was presented.

⊙ For example, a circle-circle tube swaging process was simulated.

⊙ A backpressing die approach was proposed to reflect the reverse motion of the

workpiece.

⊙ Load on the backpressing die was imposed by the virtual body force technique.