Iranian Journal of Mechanical Engineering Transactions of ISME

Iranian Journal of Mechanical Engineering Transactions of ISME

An Upper Bound Analysis of Bi-metallic Tube Drawing Process through Curved and Mandrel Profiles

Authors
Payam Haji Azizi 1
Heshmatollah Haghighat 2
1 MSc, Department of Mechanical Engineering, Razi University, Kermanshah, Iran
2 Associate Professor, Department of Mechanical Engineering, Razi University, Kermanshah, Iran
10.30506/ijmep.2025.2047227.2002
Abstract
In this paper, the bi-metallic tube drawing process with arbitrary curved die and mandrel profiles has been analyzed by the upper bound method and simulated by the finite element method. For the analysis, the bi-metallic tube has been divided into six separate regions, including four regions without deformation at the entry and exit of the die and two regions where the two tube metals are located in the space between the die and the mandrel and plastic deformation occurs in them. For each of the regions, a general velocity field in the spherical coordinate system, applicable to any arbitrary shape of the die, has been presented. Based on the proposed velocity field, the strain rate field has been obtained and then the internal, shear and frictional forces have been calculated. By equating the external power required to perform the process with the sum of the internal, shear and frictional forces, the required tensile force has been calculated. The results of the analysis method have been compared with the results of the process simulation using the finite element method, which was performed with the ABAQUS software. Finally, the effects of various parameters including the percentage of cross-sectional area reduction, tube thickness, and die angle on tensile force, optimal die angle, and shear strength between the two metals were investigated.
Keywords
Tube drawing
Upper bound
Bi-metallic tube
Curved die

Subjects

[1] Y. Wang, Y. Gao, Y. Li, Z. Wenyan, S. Liang and Z. Chao, "Review of Preparation and Application of Copper–steel Bimetal Composites," Emerging Materials Research, Vol. 8, No. 4, pp. 538–551, 2019, https://doi.org/10.1680/jemmr.17.00008.
 
[2] N. Cristescu, "A Theory of Tube Sinking," Mechanics Research Communications, Vol. 2, No. 5-6, pp. 233-238, 1975, https://doi.org/10.1016/0093-6413(75)90050-6.
 
[3] C.-T. Kwan, "A Generalized Velocity Field for Axisymmetric Tube Drawing through an Arbitrarily Curved Die with an Arbitrarily Curved Plug," Journal of Materials Processing Technology, Vol. 122, No. 2-3, pp. 213-219, 2002, https://doi.org/10.1016/S0924-0136(02)00013-4.
 
[4] H. Haghighat and G. Asgari, "A Generalized Spherical Velocity Field for Bi-metallic Tube Extrusion through Dies of any Shape," International Journal of Mechanical Sciences, Vol. 53, No. 4, pp. 248-253, 2011, https://doi.org/10.1016/j.ijmecsci.2011.01.005.
 
[5] H. Haghighat and M. Mahdavi, "Analysis and FEM Simulation of Extrusion Process of Bimetal Tubes through Rotating Conical Dies," Transactions of Nonferrous Metals Society of China, Vol. 23, No. 11, pp. 3392-3399, 2013. https://doi.org/10.1016/S1003-6326(13)62879-4.
 
[6] D. Halaczek, "Analysis of Manufacturing Bimetallic Tubes by the Cold Drawing Process," Archives of Metallurgy and Materials, Vol. 61, No. 1, pp. 241-248, 2016, http://doi.10.1515/amm-2016-0045.
 
[7] F. Barandar, M. Elyasi, M. J. Mirnia, and R. Jamaati, "The Effect of Surface Shape on the Production of Aluminum-copper Two Layer Tubes using Forward Extrusion Process," Iranian Journal of Manufacturing Engineering, Vol. 6, No. 8, pp. 1-9, 2020, (in Persian), article_101933_083dba1e2b11fe40a42c83720f9045dd.pdf.
 
[8] A. Gholizadeh, M. Elyasi, M. Mirnia, and R. Jamaati, "Experimental Investigation of the Effect of Temperature on the Production of Bimetallic Workpiece Al-Cu using Forward Extrusion Method, " Modares Mechanical Engineering, Vol. 20, No. 9, pp. 2355-2362, 2020, https://doi.org/20.1001.1.10275940.1399.20.9.14.1.
 
[9] M. -J. Mirnia, A. Fallah, and M. Elyasi, "Experimental and Numerical Investigation of the Effect of Preform on Hot Forging of Bimetallic Components from Aluminum and Brass," Modares Mechanical Engineering, Vol. 23, No. 2, pp. 67-79, 2023, https://doi.org/10.52547/mme.23.2.67.
 
[10] Avitzur, B., “Metal Forming: Processes and Analysis” McGraw-Hill, New York, 1968, Metal forming : processes and analysis | CiNii Research.
 
[11] W. Gordon, C. Van Tyne, and Y. Moon, "Axisymmetric Extrusion through Adaptable Dies—Part 1: Flexible Velocity Fields and Power Terms," International Journal of Mechanical Sciences, Vol. 49, No. 1, pp. 86-95, 2007, https://doi.org/10.1016/j.ijmecsci.2006.07.011.
 
[12] W. Gordon, C. Van Tyne, and Y. Moon, "Axisymmetric Extrusion through Adaptable Dies—Part 3: Minimum Pressure Streamlined Die Shapes," International Journal of Mechanical Sciences, Vol. 49, No. 1, pp. 104-115, 2007, https://doi.org/10.1016/j.ijmecsci.2006.07.013.
 
[13] Y.-M. Hwang and T.-F. Hwang, "An Investigation into the Plastic Deformation Behavior within a Conical Die during Domposite Rod Extrusion," Journal of Materials Processing Technology, Vol. 121, No. 2-3, pp. 226-233, 2002, https://doi.org/10.1016/S0924-0136(01)01254-7.
 
[14] A. Khosravifard and R. Ebrahimi, "Investigation of Parameters Affecting Interface Strength in Al/Cu Clad Bimetal Rod Extrusion Process," Materials & Design, Vol. 31, No. 1, pp. 493-499, 2010, https://doi.org/10.1016/j.matdes.2009.06.026.

  • Receive Date 02 December 2024
  • Revise Date 20 May 2025
  • Accept Date 03 June 2025