Abstract
This paper describes an efficient method of manufacturing thin-walled metal tubes. The proposed method is an expansion drawing and it consists of two stages, flaring and drawing, during which high thickness reduction is achieved because the tube being processed is subjected to tensile stress in both the circumferential and axial directions. The optimal plug half-angle for various materials is investigated using a finite element analysis and experiments, revealing the plug shape with the highest expansion limit and the highest thickness reduction ratio. To investigate the deformation characteristics of different materials during the expansion drawing process, the strain in tubes formed using different materials was measured experimentally using a square grid on the outer surface of the tubes. In addition, a finite element analysis using hypothetical material properties revealed that the work-hardening exponent and friction coefficient affect tube deformation. The results of this work explain the influences of material properties on experimentally observed phenomena. Materials with a large work-hardening exponent are less prone to thinning during forming and have a greater forming limit. On the other hand, the larger the friction coefficient between the plug and the mother tube, the larger the deformation in the axial direction was, and then the thickness reduction increased due to biaxial tension.
