Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Numerical Simulation and fabrication of copper thin wall tube by constrained ironing method

Document Type : Original Article

Authors
Arya Kazemzadeh 1
Ghader Faraji 2
1 MSc Graduate, Department of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran
2 Associate Professor, Department of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran
10.22034/ijme.2024.434030.1899
Abstract
One of the most widely used metal forming processes is Ironing, which is usually used as a secondary process after the deep drawing process. The Ironing process is used to reduce the wall thickness, equalize the thickness distribution of the wall, and also increase the length of the workpiece. Among the developed methods, the constrained Ironing method has provided the highest thickness reduction ratio. This method is based on converting the tensile stress to compressive stress in the deformation area. The thickness reduction percentage of 65% has been considered for this research which is simulated by the FEM method and after that experimental sample has been made by this method. Finally, due to the conversion of stress in the deformation area, this method provides the possibility of achieving a higher thickness reduction, and the mechanical properties of the sample were improved. This process, due to the application of compressive stress and high strain to the shell, has led to the reduction of the grain size and also its stretching, which has affected the mechanical properties in such a way that the microhardness of the sample has reached from 48 Vickers to 130 HV. Also, this process leads to a 120% increase in tensile strength.
Keywords
Constrained Ironing
Thickness Reduction Percentage
Finite Element Method
Microstructure
Mechanical Properties
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