FEA Based Comparative Analysis of Tube Drawing Proc Ess

Finite element analysis (FEA) simulations are extensively used in tube manipulation processes such as tube drawing, sinking and extrusion.FEA is one of the most important methods to si mulate metal forming. This work aims to find the best geometry of die and plug to r educe the drawing force, and also find the residual stresses in the tube using FEA. Die has been des igned with different semi-die angle and plug configurations which are all analyzed through FEA. Geometric, contact to contact surface and material nonlinearity are involved in this problem. The material of pipe used is steel, die and plug material used is tungsten carbide. In tube drawing, the optimum semi-die angles are identified using FEA. In this work, the cold drawing of tubes with fixed plug was sim ulated by using the commercial software Altair Hyper mesh for pre-processing and Simuilia Abacus for solving and post processing of this study. The project intends to determine the drawing force and stress, and also helps in reducing lead time and try outs and providing products free of defects and with controlled mechanic al properties