Simulation of Cold Pilgering Process by a Generalized Plane Strain FEM

Abstract

Abstract In order to attain a defect-free operation in the cold pilgering process, one must understand the material behavior through both experimental and computational study, optimization of the tool profile (mandrel and rolls), and appropriate selection of the tool material. Until now, several simplified computational methods have been presented, because 3-dimensional analysis is still far away in such a complicated forming process. In this paper, a generalized plane strain model has been employed for the simulations of cold pilgering of fuel cladding for nuclear applications. In this model, the tube material is considered to be viscoplastic at the loading stage of pilgering and totally elastic after every stroke. Therefore, considering the tube springs back after each stroke, it can be investigated how the tube shape affects deformation in the next pilgering stroke. A cold pilgering of zirconium alloy by two types of tools has been computed and compared. Moreover, computed results are compared with experimental results. Throughout the studies, the effect of tube spring back and the effect of design parameters on the deformation behavior are demonstrated.