Finite Element Simulation and Experimental Verification of Circular Tube Nosing through Conical Dies

Abstract

The process of tube nosing is a delicate art that involves forming the end of a tubular part without causing any collapse, buckling, or wrinkling. A recent study has delved into the different modes of failure that can occur during this process and has determined the limits of tube nosing through the use of plasticity and thin/thick-walled tube theories. A finite element simulation was developed to replicate the cold-nosing process using conical dies to validate these theories. The results were compared to experimental outcomes for mild steel, hard steel, and annealed aluminium tubes to ensure accuracy. Through this analysis, we identified and confirmed the modes of failure that can restrict the plastic deformation for the tube nosing process. The outcomes were compared to analytical expressions and showed excellent agreement with the experiments, proving that these expressions provide a reliable reference guide for predicting the limits of the tube-nosing process. The FE simulation method also accurately models critical buckling stresses, nosing loads, and failure modes.

Keywords

• forming limits
• axial buckling
• circumferential buckling
• wrinkling
• tube-nosing
• modes of failure