Abstract
This paper applies the incremental finite-element method of elasto-plastic large deformation analysis to the ironing process. In addition, an experimental test of the ironing process has been performed to verify the theoretical formulation. The paper is divided into two parts. The first part involves deriving the load correction and friction correction matrices which are indispensable for surface traction rate equilibrium in the updated Lagrangian formulation, following which the preparation and procedure of the experimental work is described. The second part involves numerical simulation and a comparison of the results of the numerical model with those of the experiment. The finite-element calculations also predict the forming load, the stress distribution, the plastic enclave, and the deformation history. The comparison shows good agreement between the load-displacement relations of the experiment and the finite-element predictions.
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