Finite Element Simulation of a Doubled Process of Tube Extrusion and Wall Thickness Reduction

This research deals with the forward extrusion process of tubes. In this process, a piercing process was carried out on the billet to produce the tube, followed directly by a reduction in the wall thickness. A specific geometrical shape for the piercing zone and the wall thickness reduction zone were chosen and designed. The effects of the redundant shear strain and the magnitude of the extrusion load were investigated and simulated with the finite element method using Q Form software program. Lead was used as model materials since (if the experiments were carried out at room temperature) it has the similar behavior of the steel at high temperature. The results obtained have shown that at the piercing zone, the lowest values of the extrusion load, the redundant strain, the total strain and the finite element effective strain were when a piercing tool (mandrel) of (C = 1.1) was used. While, at the die zone, the lowest values of the extrusion load, the redundant strain, the total strain was when a die of (C = 0.9) was used.