FE MODELLING OF THREE DIMENSIONAL STAGGERED BACKWARD METAL FLOW FORMING PROCESS.

A three-dimensional Finite Element (FE) model for a backward flow forming process is developed using ABAQUS simulation software. Forming parameters such as feed speed ratio, percentage reductions, and roller geometries on the stresses, forces, power, and dimensions of flow formed tubes are studied. A comparison between the traditional theoretical formulations and simulated forces is made. The impact of feed speed ratios and percentage reduction on out of roundness of flow formed tubes are studied and compared with experimental results. The closeness of the estimated power to the experimental power available in the literature shows that the developed simulated model is promising and robust. [ABSTRACT FROM AUTHOR]