Investigation into the improvement of welding strength in three dimensional extrusion of tubes using porthole dies

Solid expandable tubular is an emerging and promising technology in petroleum industry. It consists of increasing the diameter of a tubular by hydraulically pushing or mechanically pulling a conical mandrel through it. In this paper, a dy namic explicit finite element analysis (FEA) has been used to study the solid tubular expansion using ABAQUS, a commercial FEA software package. The required drawing force for tubular expansion was estimated for different mandrel shapes, friction coefficients, and expansion ratios. The drawing force increases with the increase in friction coefficient and expansion ratio. It was also found that the material velocities increase on the front of the mandrel but decrease to zero in the post expansion section. Moreover, the plastic deformation shows a reduction of thickness with friction coefficient and expansion ratio. Simulation results also revealed that contact occurs at the two ends of the conical mandrel tubular interface and that the contact stress increases wi...

Simulation of Solid Tubular Expansion in Well Drilling Using Finite Element Method

The advancements in the application of the finite-element method to metal-forming problems, emphasizing the method based on flow formulation, are presented in this paper. The developments in the areas of workability in forging, friction at the die-workpiece interface, extrusion, drawing and rolling, sheet metal forming, warm and hot forming, and three-dimensional problems are discussed with attention on underlying motivations and future directions. Further remarks are made on residual stresses in metal-forming and design problems.

Metal Forming and the Finite Element Method — Past and Future


 The purposes of this review are to summarize the historical progress in the last 60 years of lightweight metal forming, to analyze the state-of-the-art, and to identify future directions in the context of Cyber-physically enabled circular economy. In honoring the 100th anniversary of the establishment of the Manufacturing Engineering Division of ASME, this review paper first provides the impact of the metal forming sector on the economy and historical perspectives of metal forming research work published by the ASME Journal of Manufacturing Science and Engineering, followed by the motivations and trends in lightweighting. To achieve lightweighting, one needs to systematically consider: (1) materials and material characterization; (2) innovative forming processes; and (3) simulation tools for integrated part design and process design. A new approach for process innovation, i.e., the Performance-Constraints-Mechanism-Innovation (PCMI) framework, is proposed to systematically seek new processes. Finally, trends and challenges for the further development in circular economy are presented for future exploration.

Opportunities and Challenges in Metal Forming for Lightweighting: Review and Future Work

The theory of metal forming has been used to study the mechanical response of a solid tubular under radial plastic expansion. A mathematical model of an expanded thin walled tube under compression has been developed in this paper. The study showed that as the friction coefficient and mandrel angle increase the drawing force and induced stresses increase. However, the final tube thickness and length were found to decrease with an increase in both parameters.

Structural Behavior of a Solid Tubular Under Large Radial Plastic Expansion

Two solutions for the detailed mechanics of tube extrusion are presented. One is based on the theoretical velocity field, and the other on the flow field observed experimentally. The theoretical solution makes use of admissible velocity fields containing no velocity discontinuities. Experimental flow patterns are obtained for commercially pure lead and a superplastic alloy of the eutectic of lead and tin. The two solutions are compared in terms of velocity components, grid distortions, and strain and stress distributions, and very good agreement between the two solutions is revealed.

Analysis of Tube Extrusion

A method of obtaining admissible velocity fields without velocity discontinuities is described, and applied to plane-strain extrusion, tube extrusion, and axisymmetric piercing. In plane-strain extrusion, the flow lines, grid distortions, and extrusion pressures were obtained and the values were compared with those found in previous solutions. For tube extrusion and axisymmetric piercing, the solutions are presented as examples in terms of flow lines and velocity component distributions; these solutions await experimental confirmation.

A New Upper-Bound Method for Analysis of Some Steady-State Plastic Deformation Processes

Finite Element Analysis and Experimental Investigation of Sheet Metal Stretching

Closure to “Discussion of ‘A New Upper-Bound Method for Analysis of Some Steady-State Plastic Deformation Processes’” (1969, ASME J. Eng. Ind., 91, pp. 741–742)

H. S. Mehta

Papers

Analysis of Tube Extrusion

A New Upper-Bound Method for Analysis of Some Steady-State Plastic Deformation Processes

Finite Element Analysis and Experimental Investigation of Sheet Metal Stretching

Closure to “Discussion of ‘A New Upper-Bound Method for Analysis of Some Steady-State Plastic Deformation Processes’” (1969, ASME J. Eng. Ind., 91, pp. 741–742)