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Load prediction on metal forming process (tube sinking) using finite element method

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Abstract

This study focuses on the Bubnov-Galerkin finite element model used to obtain the stresses and pressure fields set up at various cross-sections of a blank during the metal forming process. Four Lagrange quadratic elements were assembled to represent the various blanks. The governing equation adopted is a one-dimensional differential equation describing the pressures and stresses exerted on the forming process. In conducting the analysis, the various blanks are divided into a finite number of elements and further applying the Bubnov-Galerkin-weighted residual method to obtain the weighted integral form; the finite element model is obtained in a matrix form, from the weighted residual boundary conditions which are now applied to obtain the pressure distribution across the cross-section of the various blanks. Finite element results are obtained for a value of the coefficient of friction, die angle, length, and blank radius. Solution of the finite element method was compared with the exact solution, along with an experimental test known as press-fit analysis using Ansys Workbench, a program-controlled mesh of polar hexahedral elements which was utilized to further validate the result. Furthermore, the use of a computer-aided software assists in visualizing the solution of the tube sinking problem. The results were all presented in both tabular and graphical modes. This study shows that there are potentials for using this approach in engineering practices to ensure that the strength of materials be considered before usage in design and fabrication. These results are expected to improve advance knowledge in manufacturing processes.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Saskatchewan, 57 Campus Drive, Saskatoon, SK, S7N 5A9, Canada

    Akinola Ogbeyemi

  2. Department of Mechanical Engineering, Michigan Technological University Houghton, Houghton, Michigan, 49931, USA

    Ikechukwu Okoh

  3. Department of Production Engineering, University of Benin, Benin City, Nigeria

    Orogo Imuero & John Akpobi

  4. Multi-Scale Additive Manufacturing Lab, University of Waterloo, 200 University Avenue West, Waterloo, Ontario, N2L 3G1, Canada

    Osezua Ibhadode

Authors
  1. Akinola Ogbeyemi
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  2. Ikechukwu Okoh
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  3. Orogo Imuero
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  4. Osezua Ibhadode
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  5. John Akpobi
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Contributions

Akinola Ogbeyemi: conceptualization, methodology, supervision, and writing (original draft). Ikechukwu Okoh: conceptualization, MATLAB data analysis, and writing (review and editing). Imuero Orogo: methodology and writing (review and editing). Osezua Ibhadode: results validation and review. John Akpobi: project administration and overall supervision.

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Correspondence to Akinola Ogbeyemi.

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Ogbeyemi, A., Okoh, I., Imuero, O. et al. Load prediction on metal forming process (tube sinking) using finite element method. Int J Adv Manuf Technol 114, 2961–2973 (2021). https://doi.org/10.1007/s00170-021-06907-9

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  • DOI: https://doi.org/10.1007/s00170-021-06907-9

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