Finite Element Simulation of the Nosing Process of Metal Tubes with a Conical Die

In this paper, the nosing process of metal tube with a conical die is investigated using the finite element method, and a series of simulations on the tube nosing process by using the program ABAQUS is carried out. The concrete process of tube nosing deformation is described. Some simulation results on tube nosing deformation such as the distributions of the Von Mises stress and effective strain, the material thickness variation of deformation zone are obtained and analyzed.

A Study on Mathematical Model of Deformation Force for Tube Nosing with Conical Die

Based on analyzing the stress-strain characters of material in nosing deformation zone, and considering two influencing factors, i.e. material thickness variation and material work-hardening, according to ignoring and considering the influence of additional bending stress at the entrance of die, and the different forms of work-hardening of metal materials, a new set of mathematical models of deformation force calculated for tube nosing with conical die are set up by utilizing slab method that belongs to one of the theoretic methods solving the problems of metal plastic forming. Furthermore, the scope of the application of every mathematical model of deformation force calculated for tube nosing with conical die is classified from conical die semi-angle and work-hardening of metal material point of view in theory.

On Eccentric Tube Nosing

Joining two tubes of different diameters has important concerns in many industries and engineering applications. An eccentric reducer is often used in such applications. Therefore, a simple and easy technique for manufacturing an eccentric reducer is of much importance. The simplest technique for producing the eccentric reducers is the tube nosing through eccentric conical dies. In this paper the finite element simulation is used to investigate the eccentric nosing of circular tubes through an eccentric conical die. Simulation is performed to investigate the plastic deformations of the deformed tube and all the possible modes of failure during the eccentric nosing process. Identification of unfavorable modes of failure in the tube nosing process lead to design modification guidelines, design of preform, and the die shape, for the eccentric nosing process. The results obtained confirmed that the modified design of the tube blank not only improves the quality of the nosed-tube product but also reduces nosing load and improves the limiting nosing ratio. Comparison with the experimental results shows that the nosing load and the modes of failure are successfully predicted by the finite element simulation. Also, a preform design for the tube blank that can produce an eccentric reducer with collar end that did not need a trimming process is introduced.