Finite element simulation of rotary swaging process of tube-shaped workpieces / Renganathan Sekar ...[et al.]

The applications of tube-shaped workpieces have been growing steadily
across many industries, thanks to its advantages like lightweight and
versatility in assembly. This increase in demand must be met with efficient
near net shape manufacturing processes like rotary swaging which is also
gaining industrial prominence in the recent years. The process investigated
in this paper is a category of recess type swaging process with mandrel
where there is no axial movement of the workpiece. Initially, the FE
methodology is validated by comparing the predictions of a similar process
with the experiments. Using the same methodology and FE tools, a FE model
is created for the rotary swaging process with six dies. The nodal velocity,
effective strain and effective stress distribution from the simulation were
investigated and a good agreement was found between the theory and
predictions. The intelligent metal forming simulator AFDEX is used for
carrying out the finite element analysis. The axial velocity is found to be
maximum in the sizing zone during the deformation process and the tubeshaped workpiece experiences triaxial stress states. This simulation
framework can be used for quicker development and optimization of process
design for tube shaped workpieces.