Die shape design of tube drawing process using FE analysis and optimization method

Abstract

The cold tube drawing has been generally regarded as an effective technology because of its high productivity and low production costs. It has been used instead of the swaging process to form monobloc tube shafts (MTSs) with a constant outer diameter or hollow shafts without defects. MTSs are used nowadays to reduce the weight of shafts and to improve power transmission in the auto industry nowadays. The objective of this study was to design an optimal die that can prevent material fracture considering critical damage value in the tube drawing process. To achieve this objective, a finite element simulation and the flexible polyhedron search method are used. The drawing die shape is represented by the Bezier curve that is able to generate all the possible die shapes. The tube drawing experiments were carried out using the optimized tool. In the experiments, it was possible to produce sound products without fracture.