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Forming process of tubes from metal rods using finite elements

Kandylas Vasileios

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Summary

The metal forming process has established itself as one of the fundamental processes in both heavy machinery component production and the manufacturing of small everyday use devices. The reason it is such a crucial process is that the range of its products spans from enhancing and upgrading production machinery to processors used in electronic computers. This process has several subcategories, differing in how the metal is shaped, the temperature at which it occurs, or the extent of deformation taking place. The primary goal of this thesis is to simulate the cold forming process of tubes from metal rods. This specific process involves reducing the cross-section of a metal rod through the use of a die without increasing its temperature. The study of this process within a simulation environment will be conducted using finite elements and the theory of plasticity. It will be examined in two stages, initially in a static loading environment and subsequently in a semi-static loading environment. The results of this study will be used to optimize the final product of the process and, at the same time, reduce energy costs. Additionally, it will enable the prediction of potential failures attributed to fractures, folds, and other imperfections.

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