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117513

STUDY OF ALUMINUM TUBE COLD NOSING PROCESS INTO CONICAL AND HEMI-SPHERICAL DIES WITH DIFFERENT COEFFICIENTS OF FRICTION

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Last updated: 04 Jan 2025

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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 were investigated. The effect of surface conditions on the load/displacement curve in the nosing process was 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 and semi die angle. The load increased with increasing the coefficient of friction to overcome friction between the die and tube. The nosing ratio increases as wall thickness increases. Comparison between analytical and FE predictions to the experimental results showed good agreement.

DOI

10.21608/jest.2020.117513

Keywords

Theoretical analysis, Finite element analysis (FEA), Hemispherical die, Conical die, Nosing ratio, Failure modes

Authors

First Name

A.

Last Name

Badran

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Affiliation

Department of Production Engineering and Mechanical Design, Faculty of Engineering, Minia University, El-Minia, EGYPT.

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First Name

S. Z.

Last Name

EL-Abden

MiddleName

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Affiliation

Department of Production Engineering and Mechanical Design, Faculty of Engineering, Minia University, El-Minia, EGYPT.

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First Name

W. Y.

Last Name

Ali

MiddleName

-

Affiliation

Department of Production Engineering and Mechanical Design, Faculty of Engineering, Minia University, El-Minia, EGYPT.

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City

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Orcid

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First Name

N.

Last Name

Elzayady

MiddleName

-

Affiliation

Mechanical and Aerospace Department, Institute of Aviation Engineering and Technology, Giza, EGYPT.

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Volume

17

Article Issue

4

Related Issue

17617

Issue Date

2020-10-01

Receive Date

2020-09-21

Publish Date

2020-10-01

Page Start

55

Page End

69

Print ISSN

2090-5882

Online ISSN

2090-5955

Article File

JEST_Volume 17_Issue 4_Pages 55-69.pdf

PDF . 483.4kB

Link

https://jest.journals.ekb.eg/article_117513.html

Detail API

https://jest.journals.ekb.eg/service?article_code=117513

Order

6

Type

Original Article

Type Code

1,211

Publication Type

Journal

Publication Title

Journal of the Egyptian Society of Tribology

Publication Link

https://jest.journals.ekb.eg/

MainTitle

STUDY OF ALUMINUM TUBE COLD NOSING PROCESS INTO CONICAL AND HEMI-SPHERICAL DIES WITH DIFFERENT COEFFICIENTS OF FRICTION

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Article

Created At

22 Jan 2023