Development of a numerical methodology for flowforming process simulation of complex geometry tubes

Nowadays, the incremental flowforming process is widely explored because of the usage of complex tubular products is increasing due to the light-weighting trend and the use of expensive materials. The enhanced mechanical properties of finished parts combined with the process efficiency in terms of raw material and energy consumption are the key factors for its competitiveness and sustainability, which is consistent with EU industry policy. As a promising technology, additional steps for extending the existing flowforming limits in the production of tubular products are required. The objective of the present research is to further expand the current state of the art regarding limitations on tube thickness and diameter, exploring the feasibility to flowform complex geometries as tubes of elevated thickness of up to 60 mm. In this study, the analysis of the backward flowforming process of 7075 aluminum tubular preform is carried out to define the optimum process parameters, machine requirements and tooling geometry as demonstration case. Numerical simulation studies on flowforming of thin walled tubular components have been considered to increase the knowledge of the technology. The calculation of the rotational movement of the mesh preform, the high ratio thickness/length and the thermomechanical condition increase significantly the computation time of the numerical simulation model. This means that efficient and reliable tools able to predict the forming loads and the quality of flowformed thick tubes are not available. This paper aims to overcome this situation by developing a simulation methodology based on FEM simulation code including new strategies. Material characterization has also been performed through tensile test to able to design the process. Finally, to check the reliability of the model, flowforming tests at industrial environment have been developed.