Finite element modelling simulation of radial forging of tubes without mandrel

Radial forging is an open forging process used for reducing the diameters of shafts, tubes, stepped shafts and axels, as well as for creating internal profiles for tubes such as rifling the gun barrels. The radial forging of tubes is usually performed over a mandrel to create an internal profile and/or size the internal diameter; but the process can also be used without a mandrel when workpiece geometry does not allow it or the internal surface quality is not critical. In some industrial applications, it may not be possible to use a mandrel inside the tubular workpiece, e.g., due to geometrical limitations of the workpiece. In this study, finite element modelling is applied to model the radial forging of tubes without a mandrel. To verify the model, the predicted radial forging load is compared with the published experimental data which shows a good agreement. Finally, the model is used to address some technical problems associated with this process and suggestions are made to overcome these problems.