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<p>The use of thin-walled tubes is an effective lightweighting approach in manufacturing. This paper presents an efficient method for the manufacturing of thin-walled tubes, namely, the expansion drawing process. The proposed process pulls the plug through the tube in the axial direction, causing the tube to expand. A series of experiments and finite element method analyses were conducted to investigate the effects of the guide part and corner section geometry on the plugs with the aim of improving the circumferential thickness distribution uniformity and inner diameter accuracy of the formed tube. The results show that the guide part can effectively reduce the thickness deviation in the circumferential direction; within the measurement range considered in this study, the longer the guide part, the more uniform the circumferential thickness distribution. Overshoot became smaller as the plug corner radius increased. A plug with a corner radius of 20 mm suppressed the overshoot, limiting it to a maximum of 0.06 mm. These results suggest that optimizing the plug geometry can significantly improve the shapeability of thin-walled tubes during the expansion drawing process. By optimizing the shape of the plug, a tube with the highest precision according to Japanese industrial standards was realized. This study provides a reference for the design and manufacturing of high-precision thin-walled tubes through the expansion drawing process.</p>

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Effect of plug geometry on forming accuracy in tube expansion drawing process

  • 期刊论文

  • 发表日期：

    2025年3月8日

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  • Shiliang Zhang,
  • Takashi Kuboki,
  • Masayoshi Akiyama,
  • Shohei Kajikawa

摘要

The use of thin-walled tubes is an effective lightweighting approach in manufacturing. This paper presents an efficient method for the manufacturing of thin-walled tubes, namely, the expansion drawing process. The proposed process pulls the plug through the tube in the axial direction, causing the tube to expand. A series of experiments and finite element method analyses were conducted to investigate the effects of the guide part and corner section geometry on the plugs with the aim of improving the circumferential thickness distribution uniformity and inner diameter accuracy of the formed tube. The results show that the guide part can effectively reduce the thickness deviation in the circumferential direction; within the measurement range considered in this study, the longer the guide part, the more uniform the circumferential thickness distribution. Overshoot became smaller as the plug corner radius increased. A plug with a corner radius of 20 mm suppressed the overshoot, limiting it to a maximum of 0.06 mm. These results suggest that optimizing the plug geometry can significantly improve the shapeability of thin-walled tubes during the expansion drawing process. By optimizing the shape of the plug, a tube with the highest precision according to Japanese industrial standards was realized. This study provides a reference for the design and manufacturing of high-precision thin-walled tubes through the expansion drawing process.