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Numerical and Experimental Analysis of the Wall Tensile Stress in Ironing

The objective of this work is to investigate of the ironing process under different important process conditions, through application of integrated approach of physical modelling and numerical finite element (FE) simulation. The original strip ironing device was developed for this purpose, thus series of experiments have been undertaken in laboratory conditions, by varying process parameters (die angle, friction conditions, workpiece and tool material, thickness reduction etc.). FE numerical simulations of selected experiments were performed, with the same value levels of process parameters. It enables the comprehensive analysis of process physics, monitoring of coupled influence of different process parameters on material deformation and stress fields in the wall of workpiece. Numerical results show good coincidence with experimental. For successful ironing process, it is necessary that the wall tension stress has the smallest possible value, which means that the contact conditions should be carefully selected.

Ironing; FE numerical analysis; experimental modelling; strip ironing device; wall tension stress; friction

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